JP7395061B2 - Stator, electric motor, blower device, stator manufacturing method, and electric motor manufacturing method - Google Patents

Description

The present disclosure relates to a stator in which a winding is wound around a stator core, an electric motor, an air blower, a method for manufacturing a stator, and a method for manufacturing an electric motor.

2. Description of the Related Art As a conventional electric motor, an inner rotor type electric motor in which a rotor is disposed on the inner periphery of a cylindrical stator is known. The stator includes a cylindrical core back, a plurality of teeth protruding from the inner circumferential surface of the core back and arranged in a circumferential direction of the core back, and a slot formed between adjacent teeth. A winding wire is wound around the teeth to form a coil. The portion of the coil that protrudes from the teeth in the direction of the central axis when viewed along the direction perpendicular to the central axis of the core back is called a coil end. When the amount of coil ends that occupy the coil increases, the cost increases due to an increase in material costs, and the electric resistance increases due to the length of the winding, reducing the efficiency of the motor.

As a method of forming a coil on the toothed portion, there is a method of inserting a coil formed in advance into an annular shape into the toothed portion. However, in such a method, since it is necessary to form the coil with a size that allows for a margin, there is a problem that the coil end becomes large. Therefore, in Patent Document 1, the core back and the tooth portion are formed separately, and the winding wire is inserted into the slot from the slot open, and the winding wire is inserted into the plurality of tooth portions arranged in the circumferential direction. A technique has been disclosed in which the coil end is made smaller by directly winding the coil end and then assembling the core back and the teeth. In addition, in the technology disclosed in Patent Document 1, by providing a coil guard extending in the circumferential direction in a portion of the insulator corresponding to the core back, the slot opening is narrowed and the coil formed in the tooth portion is moved out of the slot. It makes it difficult to stick out.

Patent No. 3102665

However, if the slot opening is narrowed as in the technique disclosed in Patent Document 1, it becomes difficult to insert the winding wire into the slot. This makes it difficult to wind the winding, making it impossible to efficiently wind the winding around the teeth, which can lead to problems such as increased costs due to longer windings and reduced motor efficiency. .

The present disclosure has been made in view of the above, and it is possible to easily insert the winding wire into the slot when winding the winding wire around the tooth portion, and to prevent the coil formed on the tooth portion from protruding out of the slot. The purpose is to obtain a stator.

In order to solve the above problems and achieve the objective, a stator according to the present disclosure includes a cylindrical core back and a plurality of core backs arranged in the circumferential direction of the core back so as to protrude from the inner circumferential surface of the core back. A toothed portion, a plurality of insulators each covering the plurality of toothed portions, and a coil formed by winding a winding wire around the toothed portion via the insulator. A slot is formed between adjacent teeth. The core back and the plurality of teeth are separated. The insulator includes a first insulator that covers one end of the tooth along the central axis of the core back, a second insulator that covers the other end of the tooth along the central axis, and a core of the tooth. and a third insulator that covers a portion outside the center of the tooth portion along the radial direction of the bag. A coil guard portion that protrudes into the slot is formed in the third insulator. A coil guard portion protruding from each of the two third insulators adjacent to the slot is arranged within each slot. One of the coil guard parts arranged in the same slot has a stepped part bent so as to be located radially inward than the other coil guard part.

According to the present disclosure, it is possible to easily insert the winding wire into the slot when winding the winding wire around the tooth portion, and the coil formed on the tooth portion is less likely to protrude outside the slot.

Exploded perspective view of the electric motor according to the first embodiment A perspective view of a stator core in Embodiment 1 Perspective view of core back in Embodiment 1 A perspective view showing a state in which a plurality of teeth in Embodiment 1 are arranged radially. An exploded perspective view showing a state before the teeth are covered with an insulator in Embodiment 1 A perspective view showing a state in which the teeth are covered with an insulator in Embodiment 1. A perspective view showing a state in which a plurality of teeth are covered with a plurality of insulators in Embodiment 1. FIG. 2 is a diagram showing a state in which a plurality of teeth are covered with a plurality of insulators in Embodiment 1, as seen along the axial direction. Diagram of the third insulator viewed along the circumferential direction Diagram of the third insulator viewed along the axial direction FIG. 9 is a diagram showing a state where a coil is being formed on the plurality of teeth shown in FIG. 8, as seen along the axial direction. FIG. 9 is a diagram showing a state in which coils are formed in the plurality of teeth shown in FIG. 8, as viewed along the axial direction. A perspective view of a stator according to Embodiment 1 A cross-sectional view of the stator according to Embodiment 1 taken in a direction perpendicular to the central axis. Cross-sectional view of tooth part Cross-sectional view of the first insulator and the second insulator FIG. 2 is a cross-sectional view showing a method for manufacturing a stator, and a diagram showing a first assembly process. FIG. 2 is a cross-sectional view showing a stator manufacturing method, and a diagram showing an arrangement process. FIG. 2 is a cross-sectional view showing a method of manufacturing a stator, and a diagram showing a winding process. Cross-sectional view of the third insulator Cross-sectional view of the third insulator Cross-sectional view of the third insulator FIG. 3 is a cross-sectional view showing the stator manufacturing method, and is a diagram showing a second assembly process. FIG. 3 is a cross-sectional view showing the stator manufacturing method, and is a diagram showing a second assembly process. FIG. 3 is a cross-sectional view showing the stator manufacturing method, and is a diagram showing a second assembly process. FIG. 3 is a cross-sectional view showing the stator manufacturing method, and is a diagram showing a second assembly process. Core back plan view A cross-sectional view of the stator according to Embodiment 2 taken in a direction perpendicular to the central axis. FIG. 3 is a cross-sectional view showing the stator manufacturing method, and is a diagram showing a second assembly process. FIG. 3 is a cross-sectional view showing the stator manufacturing method, and is a diagram showing a second assembly process. FIG. 3 is a cross-sectional view showing the stator manufacturing method, and is a diagram showing a second assembly process. A cross-sectional view of the stator according to Embodiment 3 taken in a direction perpendicular to the central axis. FIG. 3 is a cross-sectional view showing the stator manufacturing method, and is a diagram showing a second assembly process. FIG. 3 is a cross-sectional view showing the stator manufacturing method, and is a diagram showing a second assembly process. Front view of a blower according to Embodiment 4

Below, a stator, an electric motor, an air blower, a method for manufacturing a stator, and a method for manufacturing an electric motor according to embodiments will be described in detail based on the drawings.

Embodiment 1.
FIG. 1 is an exploded perspective view of the electric motor 1 according to the first embodiment. The electric motor 1 includes a stator 2, a rotor 3, a shaft portion 4, two bearings 5, and two outer shells 6 and 7. A core back 9 of the stator 2, which will be described later, is formed into a cylindrical shape having a central axis C. Hereinafter, when explaining the directions of each component of the electric motor 1, the direction parallel to the central axis C will be referred to as the axial direction, the direction perpendicular to the central axis C will be referred to as the radial direction, and the direction of rotation around the central axis C will be referred to as the circumferential direction. do. In this specification, the inner periphery and outer periphery mean the inner periphery and outer periphery of the cylindrical core back 9.

The electric motor 1 is an inner rotor type electric motor in which a rotor 3 is arranged on the inner periphery of a cylindrical stator 2. The rotor 3 is provided with a shaft portion 4 extending along the central axis C of the stator 2 . The shaft portion 4 is rotatably supported by two bearings 5. The bearing 5 is supported by an outer shell 6 and an outer shell 7. The outer shell 6 and the outer shell 7 serve as a casing in which the stator 2, rotor 3, and bearing 5 are housed. The stator 2 includes a stator core 8 and a coil 17 formed by winding a winding 16 around the stator core 8 .

FIG. 2 is a perspective view of stator core 8 in the first embodiment. The stator core 8 includes a cylindrical core back 9 and a plurality of teeth 10 that protrude radially inward from the inner peripheral surface of the core back 9 and are arranged radially. The core back 9 and the tooth portion 10 are formed by laminating a plurality of electromagnetic steel plates along the central axis C. A slot 11 is formed between adjacent teeth 10. Although the number of slots 11 is eight in this embodiment, it may be other than eight.

FIG. 3 is a perspective view of the core back 9 in the first embodiment. FIG. 4 is a perspective view showing a state in which a plurality of tooth portions 10 according to the first embodiment are arranged radially. As shown in FIGS. 3 and 4, the stator core 8 is divided into a core back 9 and tooth portions 10. The core back 9 and the tooth portion 10 are formed separately. A groove 9a is formed in the inner circumferential surface of the core back 9, into which the radially outer end of the tooth portion 10 is fitted.

FIG. 5 is an exploded perspective view showing a state before the tooth portion 10 is covered with the insulator 12 in the first embodiment. FIG. 6 is a perspective view showing a state in which the tooth portion 10 is covered with the insulator 12 in the first embodiment. The insulator 12 covers the toothed portion 10 and electrically insulates the toothed portion 10 and the coil 17 shown in FIG. 1 . The insulator 12 is made of an electrically insulating material. The electrically insulating material is, for example, resin. As shown in FIG. 5, the insulator 12 is divided into a first insulator 13, a second insulator 14, and a third insulator 15.

The first insulator 13 covers one end of the tooth portion 10 along the central axis C. The first insulator 13 has a first covering wall 13a and a first stopper portion 13b. The first covering wall 13a is a portion that covers one end surface of the tooth portion 10 in the axial direction and both side surfaces of the tooth portion 10 in the circumferential direction. The first covering wall 13a opens radially inward and outward, and also opens toward the toothed portion 10. The first stopper portion 13b serves to prevent the coil 17 from protruding radially inward. The first stopper portion 13b extends from the radially inner end of the first covering wall 13a in the direction away from the tooth portion 10 along the axial direction.

The second insulator 14 covers the other end of the tooth portion 10 along the central axis C. The second insulator 14 has a second covering wall 14a and a second stopper portion 14b. The second covering wall 14a is a portion that covers the other end surface of the tooth portion 10 in the axial direction and both side surfaces of the tooth portion 10 in the circumferential direction. The second covering wall 14a opens radially inward and outward, and also opens toward the toothed portion 10. The second stopper portion 14b serves to prevent the coil 17 from protruding inward in the radial direction. The second stopper portion 14b extends from the radially inner end of the second covering wall 14a in a direction away from the tooth portion 10 along the axial direction.

The third insulator 15 covers a portion of the tooth portion 10 outside the center of the tooth portion 10 along the radial direction. The third insulator 15 has a third covering wall 15a and a third stopper portion 15b. The third covering wall 15a is a square cylindrical portion that covers both axial end surfaces of the toothed portion 10 and both circumferential side surfaces of the toothed portion 10. The third covering wall 15a is open inward and outward in the radial direction. That is, the third covering wall 15a is a cylindrical wall that opens in the radial direction. The third stopper portion 15b serves to prevent the coil 17 from protruding outward in the radial direction. The third stopper portion 15b extends in the axial direction and the circumferential direction. A rectangular opening 15c, which is longer in the axial direction than in the circumferential direction, is formed in the center portion of the third stopper portion 15b in the circumferential direction. The third covering wall 15a projects radially inward from the periphery of the opening 15c.

FIG. 7 is a perspective view showing a state in which a plurality of tooth portions 10 are covered with a plurality of insulators 12 in the first embodiment. FIG. 8 is a diagram showing a state in which a plurality of tooth portions 10 are covered with a plurality of insulators 12 in the first embodiment, as viewed along the axial direction. Note that in FIGS. 7 and 8, illustration of the third insulator 15 is omitted. As shown in FIGS. 7 and 8, each of the plurality of teeth 10 is covered with an insulator 12. As shown in FIGS. One insulator 12 is provided for each tooth portion 10. Both radial side surfaces of each tooth portion 10 are exposed without being covered by the insulator 12. The first insulator 13 , the second insulator 14 , and the third insulator 15 are provided in the same number as the tooth portions 10 . The number of insulators 12 is appropriately increased or decreased according to the number of teeth 10.

FIG. 9 is a diagram of the third insulator 15 viewed along the circumferential direction. As shown in FIG. 9, the radially inner opening edge of the third covering wall 15a of the third insulator 15 is inclined radially inward. Specifically, the radially inner opening edge of the third covering wall 15a is inclined so as to be located radially inward from one end in the axial direction toward the other end. In other words, the length of the third covering wall 15a along the radial direction increases from one end to the other end in the axial direction.

FIG. 10 is a diagram of the third insulator 15 viewed along the axial direction. As shown in FIG. 10, three types of third insulators 15 having different circumferential end shapes are used. In the following description, when distinguishing three types of third insulators 15, they are referred to as third insulator 15A, third insulator 15B, and third insulator 15C.

A portion of the third stopper portion 15b of each of the third insulators 15A, 15B, and 15C that protrudes into the slot 11 becomes a coil guard portion 15d that closes the slot opening of the slot 11. Two coil guard portions 15d are formed in each of the third insulators 15A, 15B, and 15C. In the third insulator 15A, a stepped portion 15e is formed at the tip end in the circumferential direction of one coil guard portion 15d, and is bent so as to be located radially inward than other portions, and the other coil guard portion 15d are formed in a curved shape located on the same circumference. In the third insulator 15B, a stepped portion 15e is formed at the circumferential tip of each of the two coil guard portions 15d, and is bent so as to be located radially inward than the other portions. In the third insulator 15C, each of the two coil guard parts 15d is formed in a curved shape located on the same circumference. The stepped portion 15e is bent radially inward and extended in the radial direction, and then bent toward the adjacent tooth portion 10 and extended in the circumferential direction. A portion of the third insulator 15A and the third insulator 15B excluding the stepped portion 15e and the third insulator 15C are arranged so as to be located on the same circumference.

Inside each slot 11, a coil guard portion 15d is arranged, which projects one from each of the two third insulators 15 adjacent to the slot 11. A stepped portion 15e is formed at the circumferential tip of one of the coil guard portions 15d disposed in the same slot 11, and is bent so as to be positioned radially inward of the other circumferential tip. ing. The stepped portion 15e of one of the two coil guard portions 15d and the circumferential tip portion of the other are arranged to overlap in the radial direction. The tip end in the circumferential direction of the coil guard portion 15d is the part of the entire third insulator 15 located at the end in the circumferential direction. In the following description, the circumferential tip of the coil guard portion 15d may be referred to as one end or the other end of the third insulator 15.

FIG. 11 is a diagram showing a state where the coil 17 is being formed on the plurality of teeth 10 shown in FIG. 8, as viewed along the axial direction. FIG. 12 is a diagram showing a state in which the coils 17 are formed on the plurality of teeth 10 shown in FIG. 8, as viewed along the axial direction. FIG. 13 is a perspective view of the stator 2 according to the first embodiment. As shown in FIGS. 11 and 12, a coil 17 is formed by winding a winding 16 around the toothed portion 10 via an insulator 12.

Next, a method for manufacturing the stator 2 according to this embodiment will be described. FIG. 14 is a cross-sectional view of the stator 2 according to the first embodiment, taken in a direction perpendicular to the central axis C. Here, a case will be described in which a stator 2 having eight teeth 10 shown in FIG. 14 is manufactured, but this is not intended to limit the number of teeth 10. In the following explanation, when distinguishing the eight tooth parts 10, among the tooth parts 10 in each figure, the tooth part 10 located on the upper side and center of the page is referred to as the tooth part 10A, and in order counterclockwise from the tooth part 10A. They are referred to as tooth portion 10B, tooth portion 10C, tooth portion 10D, tooth portion 10E, tooth portion 10F, tooth portion 10G, and tooth portion 10H. The method for manufacturing the stator 2 includes a first assembly process, an arrangement process, a winding process, a second assembly process, and a third assembly process.

FIG. 15 is a cross-sectional view of the tooth portion 10. FIG. 16 is a cross-sectional view of the first insulator 13 and the second insulator 14. FIG. 17 is a sectional view showing a method for manufacturing the stator 2, and is a view showing a first assembly step. Note that the cross-sectional shapes of the first insulator 13 and the second insulator 14 are the same, so in cross-sectional views such as FIGS. There is. The first assembling step is a step of assembling the first insulator 13 and the second insulator 14 to each of the plurality of tooth portions 10. In the first assembly step, as shown in FIG. 5, the first insulator 13 and the second insulator 14 are fitted into the tooth 10 from both sides of the tooth 10 in the axial direction. By performing the first assembly process, as shown in FIG. Covered by an insulator 14.

FIG. 18 is a sectional view showing a method of manufacturing the stator 2, and is a diagram showing an arrangement process. The arrangement step is a step of arranging the plurality of tooth portions 10 covered by the first insulator 13 and the second insulator 14 side by side in the circumferential direction. In the arrangement step, the plurality of tooth parts 10 are arranged radially, and the plurality of tooth parts 10 are immovably fixed using a jig (not shown). A cylindrical space for inserting the rotor 3 shown in FIG. 1 is formed on the inner periphery of the plurality of teeth 10.

FIG. 19 is a sectional view showing a method of manufacturing the stator 2, and is a view showing a winding process. The winding step is a step of winding the winding 16 around the tooth portion 10 via the first insulator 13 and the second insulator 14 to form the coil 17. In the winding step, the winding 16 is started from the outside in the radial direction of the toothed portion 10. The winding method may be appropriately selected from known winding methods. For example, the winding 16 may be wound around the tooth portion 10 in a winding manner as shown in FIGS. 11 and 12. The coil 17 is also arranged in the slot 11 formed between adjacent teeth 10.

FIG. 20 is a cross-sectional view of the third insulator 15A. FIG. 21 is a cross-sectional view of the third insulator 15B. FIG. 22 is a cross-sectional view of the third insulator 15C. In the second assembly process, three types of third insulators 15A, 15B, and 15C shown in FIGS. 20 to 22 are used. The second assembling step is a step of assembling the third insulator 15 to each of the plurality of tooth portions 10 shown in FIG. 19 from the outside in the radial direction. In the second assembly step, as shown in FIGS. 5 and 6, a portion of the tooth portion 10 outside the center of the tooth portion 10 along the radial direction is fitted into the opening 15c of the third insulator 15. A portion of the tooth portion 10 covered by the first insulator 13 and the second insulator 14 is fitted into the opening 15c of the third insulator 15.

FIG. 23 is a cross-sectional view showing the method for manufacturing the stator 2, and is a view showing the second assembly process. FIG. 24 is a cross-sectional view showing the method for manufacturing the stator 2, and is a view showing the second assembly process. FIG. 25 is a cross-sectional view showing the method for manufacturing the stator 2, and is a view showing the second assembly step. FIG. 26 is a cross-sectional view showing the method for manufacturing the stator 2, and is a view showing the second assembly process.

First, as shown in FIG. 23, the third insulator 15B having stepped portions 15e formed at both ends in the circumferential direction is assembled to the tooth portion 10A. Subsequently, as shown in FIG. 24, a third insulator 15A having a stepped portion 15e formed at one end in the circumferential direction is assembled to the toothed portion 10B located counterclockwise next to the toothed portion 10A. At this time, the other end in the circumferential direction of the third insulator 15A where the stepped portion 15e is not formed is placed radially outside of the stepped portion 15e located counterclockwise of the previously assembled third insulator 15B. Overlay on. Thereafter, in a similar manner, as shown in FIG. 25, the third insulator 15A is assembled counterclockwise in the order of tooth portion 10C, tooth portion 10D, tooth portion 10E, tooth portion 10F, and tooth portion 10G. In each slot 11, the stepped portion 15e of one adjacent third insulator 15A is located on the radially inner side of the other third insulator 15A.

Subsequently, as shown in FIG. 26, a third insulator 15C in which the step portion 15e is not formed at both ends in the circumferential direction is assembled to the tooth portion 10H. At this time, one circumferential end of the third insulator 15C is stacked on the radially outer side of the step portion 15e located counterclockwise of the third insulator 15A assembled previously. Further, the other end in the circumferential direction of the third insulator 15C is stacked on the radially outer side of the stepped portion 15e located clockwise of the previously assembled third insulator 15B. By assembling the third insulator 15C to the tooth section 10H, the assembly of the third insulator 15 to all the tooth sections 10 is completed.

FIG. 27 is a plan view of the core back 9. The third assembling step is a step of assembling the core back 9 shown in FIG. 27 to each of the plurality of teeth 10 shown in FIG. 26. As shown in FIG. 14, in the third assembly step, one tooth portion 10 is fitted into each of a plurality of grooves 9a formed in the inner circumferential surface of the core back 9. A portion of the tooth portion 10 exposed from the third insulator 15 is fitted into the groove 9a. By performing the above steps, the stator 2 shown in FIG. 14 is completed.

The electric motor 1 is completed by inserting the rotor 3 shown in FIG. 1 into the inner periphery of the stator 2 shown in FIG. 14 and assembling the bearing 5 and the outer shells 6 and 7.

Next, the effects of the stator 2 according to this embodiment will be explained.

In this embodiment, as shown in FIGS. 3 and 4, the core back 9 and the plurality of teeth 10 are separated. In the present embodiment, as shown in FIGS. 5 and 6, the insulator 12 includes a first insulator 13 that covers one end of the toothed portion 10 along the central axis C of the core back 9, and a first insulator 13 that covers one end of the toothed portion 10 along the central axis C of the core back 9; 10, a second insulator 14 that covers the other end along the central axis C, and a third insulator 15 that covers a portion of the toothed portion 10 outside the center of the toothed portion 10 along the radial direction. ing. Further, in this embodiment, as shown in FIG. 10, the third insulator 15 is formed with a coil guard portion 15d that projects into the slot 11. With these configurations, as shown in FIG. 23, the coil 17 is formed by winding the winding 16 around the toothed portion 10, and then the third insulator 15 having the coil guard portion 15d that closes the slot opening is attached to the toothed portion 10. It becomes possible to assemble. Therefore, as shown in FIG. 19, when winding the winding 16 around the tooth part 10, the winding 16 can be inserted through the slot open which is not closed by the coil guard part 15d. The winding 16 can be easily inserted into the slot 11 during winding. This makes it easier to perform the winding work and align the windings 16, thereby suppressing an increase in cost and a decrease in the efficiency of the electric motor 1 due to the length of the windings 16. On the other hand, as shown in FIGS. 23 to 26, after the coil 17 is formed, the third insulator 15 having the coil guard part 15d that closes the slot opening is assembled to the tooth part 10. This makes it difficult for the coil 17 to protrude out of the slot 11. In particular, after forming the coil 17, by assembling the third insulator 15 to the coil 17 from the outside in the radial direction, the coil 17 can be pushed back into the slot 11. It becomes difficult to stick out.

In this embodiment, as shown in FIG. 14, a coil guard portion 15d is disposed within each slot 11 and protrudes from each of the two third insulators 15 adjacent to the slot 11. In addition, in this embodiment, one of the two coil guard parts 15d disposed in the same slot 11 has a stepped part 15e bent so as to be located inside the other coil guard part 15d in the radial direction. is formed. With these configurations, when the third insulator 15 is assembled to the tooth portion 10, the circumferential tips of the two adjacent coil guard portions 15d are arranged so as to overlap in the radial direction, and the slot 11 is Slot openings can be reliably blocked. Therefore, the electrical insulation between the coil 17 and the core back 9 can be improved.

In this embodiment, as shown in FIG. 5, the third insulator 15 has a cylindrical third covering wall 15a that opens in the radial direction. The inner opening edge slopes radially inward. This makes it easier to assemble the third covering wall 15a of the third insulator 15 to the toothed portion 10.

Embodiment 2.
Next, a stator 2A according to the second embodiment will be described with reference to FIGS. 28 to 31. FIG. 28 is a cross-sectional view of the stator 2A according to the second embodiment taken in a direction perpendicular to the central axis C. FIG. 29 is a cross-sectional view showing a method of manufacturing the stator 2A, and is a view showing a second assembly process. FIG. 30 is a cross-sectional view showing a method for manufacturing the stator 2A, and is a view showing a second assembly process. FIG. 31 is a sectional view showing a method of manufacturing the stator 2A, and is a view showing a second assembly process. This embodiment is different from the first embodiment described above in the ratio and arrangement of the three types of third insulators 15A, 15B, and 15C. In addition, in the second embodiment, the same reference numerals are given to the same parts as those in the first embodiment described above, and the description thereof will be omitted.

The method for manufacturing the stator 2A includes a first assembly process, an arrangement process, a winding process, a second assembly process, and a third assembly process. Since the first assembly process, arrangement process, winding process, and third assembly process are the same as those in Embodiment 1, their explanation will be omitted and only the second assembly process will be described.

First, as shown in FIG. 29, the third insulator 15B, which has stepped portions 15e formed at both ends in the circumferential direction, is placed at symmetrical positions across the central axis C, that is, separated by 180 degrees around the central axis C. The toothed portion 10A and the toothed portion 10E are respectively assembled at the positions shown in FIG.

Subsequently, as shown in FIG. 30, a third insulator 15A having a stepped portion 15e formed only at one end in the circumferential direction is inserted between the adjacent tooth portions 10B and 10C located counterclockwise of the tooth portion 10A. It is assembled in this order to the teeth 10F and 10G, which are adjacent to the tooth 10E in the counterclockwise direction. At this time, the other end in the circumferential direction of the third insulator 15A on which the stepped portion 15e is not formed is replaced with the step located counterclockwise among the stepped portions 15e of the third insulator 15B previously assembled. 15e or the stepped portion 15e of the previously assembled third insulator 15A. Note that the tooth portion 10B and the tooth portion 10F are arranged at symmetrical positions with the central axis C interposed therebetween. The tooth portion 10C and the tooth portion 10G are arranged at symmetrical positions with the central axis C interposed therebetween.

Subsequently, as shown in FIG. 31, a third insulator 15C in which the step portion 15e is not formed at both ends in the circumferential direction is inserted between the tooth portion 10D and the tooth portion 10D arranged at symmetrical positions with the center axis C in between. 10H. At this time, one end in the circumferential direction of the third insulator 15C is overlapped on the outside in the radial direction of the stepped portion 15e of the third insulator 15A that was assembled previously. Further, the other end in the circumferential direction of the third insulator 15C is stacked on the radially outer side of the step portion 15e located clockwise among the step portions 15e of the third insulator 15B assembled earlier. By assembling the third insulator 15C to the tooth portions 10D and 10H, the assembly of the third insulator 15 to all the tooth portions 10 is completed.

In this embodiment, in order to assemble the third insulator 15 to each tooth portion 10 arranged at symmetrical positions across the central axis C, the third insulator 15 is attached to the symmetrical positions across the central axis C of the stator 2A. The third insulator 15 can be assembled to the tooth portion 10 while applying force uniformly.

Embodiment 3.
Next, a stator 2B according to the third embodiment will be described with reference to FIGS. 32 to 34. FIG. 32 is a cross-sectional view of the stator 2B according to the third embodiment, taken in a direction perpendicular to the central axis C. FIG. 33 is a cross-sectional view showing a method for manufacturing the stator 2B, and is a view showing a second assembly process. FIG. 34 is a cross-sectional view showing the method for manufacturing the stator 2B, and is a view showing the second assembly process. This embodiment differs from the first embodiment described above in that two types of third insulators 15B and 15C are used. In addition, in Embodiment 3, the same reference numerals are given to the same parts as in Embodiment 1 described above, and the description thereof will be omitted.

The method for manufacturing the stator 2B includes a first assembly process, an arrangement process, a winding process, a second assembly process, and a third assembly process. Since the first assembly process, arrangement process, winding process, and third assembly process are the same as those in Embodiment 1, their explanation will be omitted and only the second assembly process will be described.

First, as shown in FIG. 33, a third insulator 15B having stepped portions 15e formed at both ends in the circumferential direction is placed between a toothed portion 10A and a toothed portion disposed at positions 90 degrees apart from each other around the central axis C. 10C, tooth portion 10E, and tooth portion 10G, respectively.

Subsequently, as shown in FIG. 34, a third insulator 15C in which the step portion 15e is not formed at both ends in the circumferential direction is connected to a tooth portion 10B disposed at a position 90 degrees apart from the central axis C. They are assembled to the teeth 10D, 10F, and 10H, respectively. That is, the third insulator 15C is arranged between two adjacent third insulators 15B. At this time, both ends of the third insulator 15C in the circumferential direction are overlapped on the radially outer side of the stepped portion 15e of the adjacent third insulator 15B. By assembling the third insulator 15C to the tooth portion 10B, tooth portion 10D, tooth portion 10F, and tooth portion 10H, respectively, the attachment of the third insulator 15 to all the tooth portions 10 is completed.

In this embodiment, the stator 2 can be manufactured using only two types of third insulators 15, the third insulator 15B and the third insulator 15C. Note that the method of assembling the third insulator 15 according to this embodiment can be used when the number of teeth 10 is an even number.

Embodiment 4.
Next, with reference to FIG. 35, a blower 18 according to the fourth embodiment will be described. FIG. 35 is a front view of the blower 18 according to the fourth embodiment. In the fourth embodiment, the same parts as those in the first embodiment described above are given the same reference numerals and the explanation thereof will be omitted.

As shown in FIG. 35, the electric motor 1 may be used as a blower 18 that connects blades 19 to the shaft portion 4 and rotates the blades 19 to blow air. Note that the electric motor 1 may be used as a ventilation fan that rotates blades or impellers to cause air to flow.

The configurations shown in the embodiments above are merely examples, and can be combined with other known techniques, or the embodiments can be combined without departing from the gist. It is also possible to omit or change part of the configuration within the scope.

1 Electric motor, 2, 2A, 2B Stator, 3 Rotor, 4 Shaft, 5 Bearing, 6, 7 Outer shell, 8 Stator core, 9 Core back, 9a Groove, 10, 10A, 10B, 10C, 10D, 10E , 10F, 10G, 10H tooth portion, 11 slot, 12 insulator, 13 first insulator, 13a first covering wall, 13b first stopper portion, 14 second insulator, 14a second covering wall, 14b 2 stopper part, 15, 15A, 15B, 15C third insulator, 15a third covering wall, 15b third stopper part, 15c opening, 15d coil guard part, 15e step part, 16 winding, 17 coil, 18 blower, 19 blade, C central axis.

Claims (6)

A cylindrical core back,
a plurality of teeth arranged in the circumferential direction of the core back so as to protrude from the inner peripheral surface of the core back;
a plurality of insulators respectively covering the plurality of teeth;
a coil formed by winding a winding around the teeth through the insulator;
A slot is formed between the adjacent teeth,
The core back and the plurality of teeth are divided,
The insulator is
a first insulator that covers one end of the tooth portion along the central axis of the core back;
a second insulator that covers the other end of the tooth portion along the central axis;
a third insulator that covers a portion of the tooth portion outside the center of the tooth portion along the radial direction of the core back;
A coil guard portion protruding into the slot is formed in the third insulator,
The coil guard portion protruding from each of the two third insulators adjacent to the slot is arranged in each slot,
One of the coil guard parts disposed in the same slot is formed with a stepped part bent so as to be located radially inward than the other coil guard part. stator. The third insulator has a cylindrical covering wall opening in the radial direction,
The stator according to claim 1 , wherein the radially inner opening edge of the covering wall is inclined radially inward. The stator according to claim 1 or 2 ,
An electric motor comprising: a rotor disposed on the inner periphery of a plurality of the teeth. A blower device comprising the electric motor according to claim 3 . A cylindrical core back, a plurality of teeth arranged in the circumferential direction of the core back so as to protrude from an inner circumferential surface of the core back, a plurality of insulators each covering the plurality of teeth, and the insulator. a coil formed by winding a winding wire around the teeth through a slot, a slot is formed between the adjacent teeth, and the core back and the plurality of teeth are connected to each other. , the insulator is divided into a first insulator that covers one end of the tooth portion along the central axis of the core back, and a first insulator that covers the other end of the tooth portion along the central axis of the core back. It is divided into a second insulator and a third insulator that covers a portion of the tooth portion outside the center of the tooth portion along the radial direction of the core back, and the third insulator includes: A method for manufacturing a stator in which a coil guard portion protruding into the slot is formed, the method comprising:
a first assembling step of assembling the first insulator and the second insulator to each of the plurality of teeth;
an arrangement step of arranging a plurality of the tooth portions side by side in the circumferential direction;
a winding step of winding the winding around the tooth portion via the first insulator and the second insulator to form the coil;
a second assembling step of assembling the third insulator to each of the plurality of teeth from the outside in the radial direction;
a third assembly step of assembling the core back to each of the plurality of teeth;
A method for manufacturing a stator, comprising: 6. A method for manufacturing an electric motor, comprising arranging a rotor on an inner periphery of a plurality of teeth in the stator manufactured by the method for manufacturing a stator according to claim 5 .

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