JP7843450B2 - Stators, motors, and application equipment - Google Patents

Description

This disclosure relates to stators, motors, and application equipment.

As a conventional stator, the armature described in Patent Document 1 is known. In this armature, a pair of insulating slot cells are attached to both sides of the teeth of the armature core. The upper part of the slot cells is then fixed by an upper bobbin covering the top surface of the teeth, and the lower part of the slot cells is fixed by a lower bobbin covering the bottom surface of the teeth.

Japanese Patent Publication No. 2020-78121

However, in the armature described in Patent Document 1, it is necessary to maintain the state in which a pair of slot cells are in contact with the teeth, and then to insert the ends of the slot cells into the bobbin to fix them in place. Therefore, the process of attaching such slot cells to the armature is complicated and difficult even when done manually, and automating this process by machine is even more difficult.

Therefore, this disclosure aims to provide a stator, motor, and application equipment that facilitates the attachment of an insulating sheet to the core and enables automated processing by machine.

A stator according to one aspect of this disclosure comprises a cylindrical yoke with a plurality of yoke portions connected together, a core having teeth extending radially inward from the inner surface of the yoke portion toward the axis of the yoke, a coil with wire wound around the teeth, a pair of insulators covering both axial ends of the core parallel to the axis, and an insulating sheet insulating the core from the coil. The insulating sheet has a teeth insulating portion covering the side surface of the teeth parallel to the axial direction, a yoke insulating portion with one end connected to the outer end of the teeth insulating portion in the radial direction and covering the inner surface of the yoke portion, a pair of extensions extending from the yoke insulating portion in one and the other axial direction, and a bent portion extending from the extensions and bending outward opposite to the radial inward direction. The insulator has a recess recessed in its inner surface into which the bent portion is fitted.

According to each aspect of this disclosure, the attachment of the insulating sheet to the core can be facilitated, and automation by machine can also be enabled.

This is a perspective view of a stator according to Embodiment 1 of the present disclosure. This is a top view of an electric motor equipped with a stator. This is a perspective view of the stator, insulator, and insulating sheet. This is a perspective view of the insulator shown above. This is a view of the upper insulator from below. These are diagrams showing the insulating sheet from above and from the inside in the radial direction. This diagram shows the insulating sheet fitted into the second recess. This diagram shows an insulating sheet pressed against the side of the teeth. This diagram shows the insulating sheet pressed against the inner surface of the yoke. This diagram shows the bent portion of the insulating sheet fitted into the first recess. This diagram shows teeth with an insulating sheet attached and wires wrapped around the insulating portion of the teeth. This diagram shows a coil covered with the coil insulation portion of an insulating sheet. This is a perspective view showing the core and insulator with insulating sheets attached. This is a perspective view showing teeth with an insulating sheet attached and wire wrapped around the insulating part of the teeth. This is a schematic diagram showing an application device according to Embodiment 3.

(Embodiment 1)
<Stator>
The stator 10 according to Embodiment 1 of the present disclosure comprises a core 18, a coil 13, and an insulator 30, as shown in the example in Figures 1 and 2. The core 18 has a cylindrical yoke 11. The axial direction parallel to the axis 11a of the yoke 11 is referred to as the vertical direction. In the radial direction of the yoke 11 centered on the axis 11a, the direction toward the axis 11a is referred to as the inward direction, and the opposite direction is referred to as the outward direction. The intersecting direction that crosses the axial and radial directions is referred to as the left-right direction. However, the arrangement of the stator 10 is not limited thereto.

The stator 10 is formed by a plurality of segments 12 (nine in the example shown in Figure 1). Each segment 12 has a core portion 20 including a yoke portion 21 and teeth 22 (Figure 8A), a coil 13 in which wire 13a (Figure 8A) is wound around the teeth 22, and a pair of insulators 30 that cover the upper and lower ends of the core portion 20 in the vertical direction. The yoke portion 21 has a substantially arc-shaped cross-section perpendicular to the axial direction, with a projection 25 extending vertically from the upper end to the other end of one side in the left-right direction, and a recess 26 extending vertically from the upper end to the other end of the other side. Nine yoke portions 21 are arranged to form a cylindrical yoke 11 such that the projection 25 of one adjacent yoke portion 21 fits into the recess 26 of the other adjacent yoke portion 21. The stator 10 is then formed by fixing the yoke portions 21 adjacent to each other in the circumferential direction by welding or the like. In this stator 10, nine core portions 20 are connected to form an annular core 18, and among these core portions 20, the yoke portion 21 constitutes the yoke 11.

<Core part>
As shown in the example in Figure 3, the core portion 20 of the segment 12 is formed by fastening together multiple steel plates stacked vertically. The core portion 20 has a yoke portion 21, teeth 22, and a wide portion 23. The core portion 20 has an upper surface and a lower surface, which are end faces that intersect (for example, perpendicular to) the vertical direction. Mounting holes 24 are provided on each of the upper and lower surfaces. Except for the protrusions 25 and recesses 26, the core portion 20 has a shape that is symmetrical with respect to a radially extending centerline.

The yoke portion 21 has an outer surface and an inner surface that intersect (for example, perpendicular to) the radial direction. For example, the outer surface is a curved surface that curves in a substantially arc shape in the left-right direction and extends linearly in the up-down direction, while the inner surface is a flat surface parallel to both the up-down and left-right directions. Furthermore, the yoke portion 21 has a right side and a left side as sides that intersect with the left-right direction. A projection 25 is provided on the right side, and a recess 26 is provided on the left side.

The teeth 22 are positioned in the center of the yoke portion 21 in the left-right direction and project radially inward from the inner surface of the yoke portion 21. Therefore, the inner surface of the yoke portion 21 has a right inner surface positioned to the right of the teeth 22, and a left inner surface positioned to the left of the teeth 22. The teeth 22 are, for example, rectangular parallelepiped and have a right side and a left side as sides that intersect (e.g., orthogonal) with respect to the left-right direction. The right and left sides are, for example, planar.

The wide portion 23 is connected to the inner end of the teeth 22. In the left-right direction, the width of the wide portion 23 is wider than the width of the teeth 22 and narrower than the width of the yoke 11. The wide portion 23 has an inner surface and an outer surface that intersect (for example, perpendicular to) the radial direction, and a side surface that intersects in the left-right direction and connects the inner surface and the outer surface. The inner surface is a curved surface that curves in a substantially arc shape in the left-right direction and extends linearly in the up-down direction. The outer surface is planar and inclined radially inward with respect to the direction away from the teeth 22 in the left-right direction. This outer surface has a right outer surface located to the right of the teeth 22 and a left outer surface located to the left of the teeth 22, and faces the inner surface of the yoke portion 21 in the radial direction. The space enclosed by the right outer surface of the wide portion 23, the right side surface of the teeth 22, and the right inner surface of the yoke portion 21 is used as the right slot 27. The space enclosed by the left outer surface of the wide section 23, the left side of the teeth 22, and the left inner surface of the yoke section 21 is used as the left slot 27. The coil 13 (Figure 8A), in which the wire 13a (Figure 8A) is wound around the teeth 22, is housed in the right and left slots 27.

<Insulator>
As shown in the examples in Figures 3 to 4B, the insulator 30 is made of an electrically insulating resin or the like and has an upper insulator 30 that is attached to the upper surface of the core portion 20 and a lower insulator 30 that is attached to the lower surface of the core portion 20. A projection 35 is provided on the lower surface of the upper insulator 30 and on the upper surface of the lower insulator 30. The insulator 30 is attached to the core portion 20 by inserting this projection 35 into the mounting hole 24 of the core portion 20.

The insulator 30 has a yoke covering portion 31, a teeth covering portion 32, a wide covering portion 33, and a protruding portion 34. The yoke covering portion 31 of the upper insulator 30 is provided with an inlet 36 through which the wires 13a of the coil 13 are introduced. Except for this inlet 36, the upper insulator 30 has a symmetrical shape with respect to a radially extending centerline. The lower insulator 30 also has a symmetrical shape with respect to a radially extending centerline.

The yoke covering portion 31 of the upper insulator 30 covers the upper surface of the yoke portion 21, and the yoke covering portion 31 of the lower insulator 30 covers the lower surface of the yoke portion 21. The inner surface of the yoke covering portion 31 is planar, and a first recess 37 is provided that extends radially outward from this inner surface. Both the upper and lower yoke covering portions 31 have a first recess 37 to the right of the tooth covering portion 32 and a first recess 37 to the left of the tooth covering portion 32, respectively. The upper first recess 37 extends vertically and opens to the lower surface of the yoke covering portion 31, and the lower first recess 37 extends vertically and opens to the upper surface of the yoke covering portion 31.

The first recess 37 is formed by the first inclined surface 37a and the first locking surface 37b of the yoke covering portion 31, without penetrating the yoke covering portion 31 radially. The angle between the first inclined surface 37a and the first locking surface 37b is less than 90 degrees, for example, 45 degrees or less. The first inclined surface 37a of the first recess 37 is, for example, a planar surface inclined with respect to the inner surface of the yoke covering portion 31 at a certain angle, and is inclined radially outward from the inner surface of the yoke covering portion 31 as it moves away from the teeth covering portion 32 in the left-right direction. The first locking surface 37b of the first recess 37 extends from the end of the first inclined surface 37a, which is farther away from the teeth covering portion 32 in the left-right direction, toward the inner surface of the yoke covering portion 31, such that the angle it makes with the first inclined surface 37a is acute, either radially inward or perpendicular to the left-right direction.

In the example shown in Figure 3, the first recess 37 has a triangular cross-section in the vertical direction, but it is not limited to this shape as long as it is formed by the first locking surface 37b. For example, the first recess 37 may have a square cross-section in the vertical direction. In this case, among the surfaces forming the first recess 37, the surface that intersects with the left-right direction and is away from the teeth covering portion 32 may be used as the first locking surface 37b.

The tooth covering portion 32 of the upper insulator 30 covers the upper surface of the tooth 22, and the tooth covering portion 32 of the lower insulator 30 covers the lower surface of the tooth 22. The tooth covering portion 32 protrudes radially inward from the inner surface of the yoke covering portion 31 at the center of the yoke covering portion 31 in the left-right direction.

The wide covering portion 33 of the upper insulator 30 covers the upper surface of the wide portion 23, and the wide covering portion 33 of the lower insulator 30 covers the lower surface of the wide portion 23. The inner surface of the wide covering portion 33 is curved in an arc shape in the left-right direction. The outer surface of the wide covering portion 33 is planar and intersects (for example, perpendicularly) with the side surfaces (right and left surfaces) of the tooth covering portion 32. The upper second recess 38 and the lower second recess 38 each have a right second recess 38 located to the right of the tooth covering portion 32 in the left-right direction, and a left second recess 38 located to the left of the tooth covering portion 32. The wide covering portion 33 is provided with an upper second recess 38 that recesses radially inward from its outer surface. The upper second recess 38 extends vertically and opens to the lower surface of the wide covering portion 33, and the lower second recess 38 extends vertically and opens to the upper surface of the wide covering portion 33.

The second recess 38 is formed by the second inclined surface 38a and the second locking surface 38b of the wide covering portion 33, without penetrating the wide covering portion 33 radially. The angle between the second inclined surface 38a and the second locking surface 38b is less than 90 degrees, for example, 45 degrees or less. The second inclined surface 38a of the second recess 38 is, for example, a planar shape inclined with respect to the outer surface of the wide covering portion 33 at a certain angle, and is inclined radially inward as it moves away from the teeth covering portion 32 in the left-right direction from the outer surface of the wide covering portion 33. The second locking surface 38b of the second recess 38 extends from the end of the second inclined surface 38a, which is farther away from the teeth covering portion 32 in the left-right direction, to the outer surface of the wide covering portion 33, such that the angle it makes with the second inclined surface 38a is acute, either radially inward or in a direction perpendicular to the left-right direction.

The protruding portion 34 has an upper protruding portion 34 that protrudes downward from the upper wide covering portion 33, and a lower protruding portion 34 that protrudes upward from the lower wide covering portion 33. Each of the upper and lower protruding portions 34 has a right protruding portion 34 that protrudes from the wide covering portion 33 along the right end of the wide portion 23, and a left protruding portion 34 that protrudes from the wide covering portion 33 along the left end of the wide portion 23. The right protruding portion 34 extends to extend the right side portion between the second locking surface 38b of the second recess 38 and the right side surface of the wide covering portion 33. The left protruding portion 34 extends to extend the left side portion between the second locking surface 38b of the second recess 38 and the left side surface of the wide covering portion 33. Therefore, the protruding portion 34 has a second locking extension surface 34a that extends the second locking surface 38b.

As shown in the examples in Figures 3 and 4B, when the insulator 30 is attached to the core portion 20, the inner surface of the yoke covering portion 31 is arranged so as to be seamless with the inner surface of the yoke portion 21 and to extend the inner surface of the yoke portion 21, forming an outer surface for the slot 27 together with the inner surface of the yoke portion 21. Furthermore, the upper yoke covering portion 31 covers the upper surface of the yoke portion 21, and the opening below the first recess 37 in the upper yoke covering portion 31 is closed by the upper surface of the yoke portion 21. The lower yoke covering portion 31 covers the lower surface of the yoke portion 21, and the opening above the first recess 37 in the lower yoke covering portion 31 is closed by the lower surface of the yoke portion 21. Additionally, the side surface of the tooth covering portion 32 is arranged so as to be seamless with the side surface of the tooth 22 and to extend the side surface of the tooth 22, forming a side surface for the slot 27 together with the side surface of the tooth 22.

The inner surface of the wide covering portion 33 is arranged so as to be seamless with the inner surface of the wide portion 23 and to extend the inner surface of the wide portion 23. The second inclined surface 38a of the wide covering portion 33 is arranged so as to be seamless with the outer surface of the wide portion 23 and to extend the outer surface of the wide portion 23, and together with the outer surface of the wide portion 23, it forms the inner surface for the slot 27. The upper projection 34 extends downward from the upper end of the wide portion 23 and covers the upper part of the side surface of the wide portion 23. The lower projection 34 extends upward from the lower end of the wide portion 23 of the core portion 20 and covers the lower part of the side surface of the wide portion 23. As a result, a gap is provided between the upper projection 34 and the lower projection 34, and the side surface of the wide portion 23 is exposed in this gap. The projections 34 protrude radially outward from the outer surface of the wide portion 23. A third recess 39 is formed between the outer surface of the wide portion 23 and the second locking extension surface 34a of the protruding portion 34, and this third recess 39 is connected to the second recess 38 of the wide covering portion 33.

<Insulating Sheet>
Figure 5 shows a top view of the insulating sheet 40 and a view of the insulating sheet 40 from the inside in the radial direction. Figure 5(a) is a top view of the insulating sheet 40, and Figure 5(b) is a view of the insulating sheet 40 from the inside in the radial direction. As shown in the examples in Figures 3 and 5, the insulating sheet 40 is made of an electrically insulating resin or the like, is a thin sheet, and has elasticity and flexibility. The insulating sheet 40 electrically insulates between the core portion 20 and the coil 13 (Figure 8A), and between the coils 13 (Figure 2) of two adjacent core portions 20. Two such insulating sheets 40 are attached to one core portion 20. Specifically, the right insulating sheet 40 is attached to the right slot 27 of one core portion 20, and the left insulating sheet 40 is attached to the left slot 27. The right insulating sheet 40 and the left insulating sheet 40 have a symmetrical shape with respect to a plane perpendicular to the left-right direction, including the center line of the radially extending teeth 22. Therefore, when viewed individually, the right insulating sheet 40 and the left insulating sheet 40 have the same shape. The right insulating sheet 40 will be described as a representative example below.

The insulating sheet 40 has a symmetrical shape with respect to a plane perpendicular to the vertical direction. The insulating sheet 40 includes a coil insulating section 41, a yoke insulating section 42, a tooth insulating section 43, a wide insulating section 44, and an extended insulating section 45. The coil insulating section 41, yoke insulating section 42, tooth insulating section 43, wide insulating section 44, and extended insulating section 45 are arranged in this order and formed integrally. The insulating sheet 40 is formed, for example, by cutting and folding a single sheet. Folds extending in the vertical direction are provided between each of the coil insulating section 41, yoke insulating section 42, tooth insulating section 43, and wide insulating section 44.

The coil insulation portion 41 is rectangular in shape and is longer than the length of the core portion 20 in the vertical direction. The left end of the coil insulation portion 41 is connected to the right end of the yoke insulation portion 42. A vertically extending fold 41a is provided between the coil insulation portion 41 and the yoke insulation portion 42, extending linearly diagonally outward from the right end of the yoke insulation portion 42. Viewed from above, the central angle of the arc extending from the outer surface of the yoke insulation portion 42 to the outer surface of the coil insulation portion 41, centered on the fold 41a, is 90 degrees or greater.

The yoke insulation portion 42 is rectangular in shape, extends in the left-right direction, and covers the entire inner surface of the yoke portion 21. Its length in the vertical direction is greater than or equal to the length of the yoke portion 21, and its length in the left-right direction is the same as or slightly longer than the length of the yoke portion 21. Furthermore, since the length of the yoke portion 21 in the vertical direction is less than the distance between the upper first recess 37 and the lower first recess 37 in the segment 12 to which the insulator 30 is attached to the core portion 20, the yoke insulation portion 42 does not cover the first recess 37. The left end of the yoke insulation portion 42 is connected to the outer end of the teeth insulation portion 43, and it extends to the right from the outer end of the teeth insulation portion 43. Viewed from above, the central angle of the arc from the right surface of the teeth insulation portion 43 to the inner surface of the yoke insulation portion 42, centered on the fold between the yoke insulation portion 42 and the teeth insulation portion 43, is, for example, 90 degrees or slightly greater. An upper extension 46 is provided at the upper end of the yoke insulating portion 42, and a lower extension 46 is provided at the lower end of the yoke insulating portion 42.

The upper extension 46 extends upward from the upper end of the yoke insulation 42, and the lower extension 46 extends downward from the lower end of the yoke insulation 42. Each of the upper and lower extensions 46 has a width narrower than the yoke insulation 42 in the left-right direction and is positioned closer to the left end of the yoke insulation 42 than to the right end. The extensions 46 are, for example, trapezoidal, and their width in the left-right direction increases as they approach the end of the yoke insulation 42 in the vertical direction. Therefore, each extension 46 can ensure a wide connection to the yoke insulation 42 and minimize separation from the yoke insulation 42.

The upper extension 46 has a notch at its left end so that it slopes diagonally upward to the right from the upper end of the yoke insulation 42. The lower extension 46 has a notch at its left end so that it slopes diagonally downward to the right from the lower end of the yoke insulation 42. As shown in the examples in Figures 9 and 10, these notches prevent the inlet 36 of the yoke covering 31 from being blocked by the yoke insulation 42, making it easier for the wire 13a of the coil 13 to be introduced from the inlet 36 into the slot 27. Furthermore, as shown in the examples in Figures 3 and 5, the upper extension 46 is connected to the upper bent portion 47, and the lower extension 46 is connected to the lower bent portion 47. A vertically separating space is formed between the lower end of the upper bent portion 47 and the upper end of the yoke insulation 42, and a vertically separating space is also formed between the upper end of the lower bent portion 47 and the lower end of the yoke insulation 42.

The bent portion 47 is rectangular in shape, with its left end connected to the right end of the extension portion 46, and extends from the extension portion 46, bending radially outward. The bent portion 47 extends from the extension portion 46 in a direction away from the teeth insulation portion 43 in the left-right direction, and is bent from the extension portion 46 such that the right end, which is the tip, is located radially outward from the left end, which is the base end, in the left-right direction. As a result, a fold extending in the vertical direction is created between the extension portion 46 and the bent portion 47. When viewed from above, the central angle of the arc from the outer surface of the extension portion 46 to the outer surface of the bent portion 47, centered on the fold between the extension portion 46 and the bent portion 47, is, for example, 90 degrees or more. In the left-right direction, the right end 47a of the bent portion 47 is located to the left of the right end of the yoke insulation portion 42. Therefore, as shown in the examples in Figures 9 and 10, the extension portion 46 is positioned on the inner surface of the yoke insulating portion 42 to the left of the first recess 37, the bent portion 47 is fitted into the first recess 37, and the right end of the bent portion 47 is locked to the first locking surface 37b.

As shown in the examples in Figures 3 and 5, the tooth insulation portion 43 is rectangular in shape, extends radially, and covers the entire side surface of the tooth 22, which is parallel to the vertical direction. Its length in the vertical direction is greater than or equal to the length of the tooth 22, and its length in the radial direction is equal to or approximately equal to the length of the tooth 22. The inner end of the tooth insulation portion 43 is connected to the left end of the wide insulation portion 44. Viewed from above, the central angle of the arc extending from the outer surface of the wide insulation portion 44 to the right surface of the tooth insulation portion 43, centered on the fold between the wide insulation portion 44 and the tooth insulation portion 43, is, for example, slightly greater than 90 degrees.

The wide insulating portion 44 is rectangular in shape, and its vertical length is greater than or equal to the length of the wide portion 23, so as to cover the entire outer surface of the wide portion 23. In the inclined direction along the outer surface of the wide portion 23, its length is the same as or approximately the same as the length of the wide portion 23. The left end of the wide insulating portion 44 is connected to the inner end of the teeth insulating portion 43, and it inclins inward from the inner end of the teeth insulating portion 43 toward the right. The right end 44a of the wide insulating portion 44 is further away from the teeth insulating portion 43 in the left-right direction than its left end, and is a locking end that engages with the protruding portion 34 of the insulator 30.

The extended insulating portion 45 has its left end connected to the right end of the wide insulating portion 44. The extended insulating portion 45 inclines inward to the right from the right end 44a of the wide insulating portion 44, so as to extend the wide insulating portion 44. Therefore, there is no fold between the extended insulating portion 45 and the wide insulating portion 44. The extended insulating portion 45 has a notch, and in the vertical direction, the length of the extended insulating portion 45 is shorter than the length of the wide insulating portion 44. The extended insulating portion 45 is positioned in the vertical center of the wide insulating portion 44, and the right end 44a of the wide insulating portion 44 extends above and below the extended insulating portion 45. Therefore, the notch of the extended insulating portion 45 is located at the upper and lower ends of the extended insulating portion 45. As shown in the examples in Figures 9 and 10, in the vertical direction, the length of the extended insulating portion 45 is the same as or slightly shorter than the length between the lower end of the upper protrusion 34 and the upper end of the lower protrusion 34. The extended insulating portion 45 has a notch into which the protruding portion 34 fits, and it protrudes to the right from between the upper protruding portion 34 and the lower protruding portion 34.

<Method for fabricating a stator>
As shown in the example in Figure 3, the projection 35 of the upper insulator 30 is inserted into the mounting hole 24 on the upper surface of the core portion 20, and the projection 35 of the lower insulator 30 is inserted into the mounting hole 24 on the lower surface of the core portion 20, thereby attaching the upper and lower insulators 30 to the core portion 20. Then, as shown in the example in Figure 6A, the stretched insulating portion 45 is inserted between the upper projection 34 and the lower projection 34. As a result, the upper end of the stretched insulating portion 45 is locked to the lower end of the upper projection 34, and the lower end of the stretched insulating portion 45 is locked to the upper end of the upper projection 34, so that the insulating sheet 40 is positioned vertically relative to the core portion 20.

Next, the right end 44a of the wide insulating portion 44 of the insulating sheet 40 is inserted into the second recess 38 and the third recess 39, and then pressed against the outer surface of the wide portion 23. At this time, the right end 44a of the wide insulating portion 44 is locked to the second locking surface 38b and the second locking extension surface 34a as a locking end. Because the wide insulating portion 44 rotates inward around this right end 44a, the outer surface of the wide portion 23 can be easily covered by the wide insulating portion 44.

Next, as shown in the example in Figure 6B, the tooth insulating portion 43 is pressed against the side surface of the tooth 22. At this time, the fold between the wide insulating portion 44 and the tooth insulating portion 43 fits into the corner between the wide portion 23 and the tooth 22. Because the tooth insulating portion 43 rotates to the left around its inner end, which forms this fold, the side surface of the tooth 22 can be easily covered by the tooth insulating portion 43.

Next, as shown in the example in Figure 7A, the yoke insulation portion 42 is pressed against the inner surface of the yoke portion 21. At this time, the fold between the teeth insulation portion 43 and the yoke insulation portion 42 fits into the corner between the teeth 22 and the yoke portion 21. Because the yoke insulation portion 42 rotates outward around its left end, which forms this fold, the inner surface of the yoke portion 21 is easily covered by the yoke insulation portion 42. The yoke insulation portion 42 and the wide insulation portion 44 are positioned radially on either side of the teeth insulation portion 43 and are supported radially by the yoke portion 21 and the wide portion 23. Therefore, the insulating sheet 40 is restricted from moving radially and is held radially by the core portion 20.

Furthermore, as shown in the example in Figure 7B, the yoke insulation portion 42 is connected to the upper bent portion 47 via the upper extension portion 46 and to the lower bent portion 47 via the lower extension portion 46. Therefore, the upper bent portion 47 and the lower bent portion 47 move outward together with the yoke insulation portion 42. Here, the upper first recess 37 is positioned outside the upper bent portion 47 and faces the upper bent portion 47. The lower first recess 37 is positioned outside the lower bent portion 47 and faces the lower bent portion 47. Also, the bent portion 47 is bent radially outward more than the yoke insulation portion 42. Therefore, as the yoke insulation portion 42 rotates, the bent portion 47 is inserted into the first recess 37. This bent portion 47 extends diagonally outward to the right along the first inclined surface 37a, and the right end 47a of the bent portion 47 faces the first locking surface 37b as a locking end and is locked by the first locking surface 37b. By being locked in place by both the upper and lower bends 47, the insulating sheet 40 is restricted from moving to the right and is held in place on the core portion 20 in the left-right direction. Thus, the insulating sheet 40 is attached to the core portion 20 by inserting the stretched insulating portion 45 of the insulating sheet 40 between the upper and lower protrusions 34, and then sequentially pressing the wide insulating portion 44, tooth insulating portion 43, and yoke insulating portion 42 against the core portion 20. This facilitates the attachment of the insulating sheet 40 to the core portion 20 of the core 18, making automated installation by machine possible.

In this way, the right insulating sheet 40 is fitted into the right slot 27 and attached to the core portion 20. Also, as shown in the example in Figure 8A, similar to the right insulating sheet 40, the left insulating sheet 40 is fitted into the left slot 27 and attached to the core portion 20. The coil insulating portion 41 of these insulating sheets 40 is inclined radially outward with respect to the yoke insulating portion 42. Furthermore, the first recess 37 for fixing the insulating sheet 40 to the core portion 20 is recessed from the inner surface of the yoke covering portion 31, and the bent portion 47 is fitted into this first recess 37, so they do not protrude from the inner surface of the yoke covering portion 31. As a result, the coil insulating portion 41 and the bent portion 47 do not intrude into the path when winding the wire 13a around the teeth 22 and the teeth covering portion 32. Therefore, the coil insulating portion 41 and the bent portion 47 do not get in the way, and the wire 13a can be easily wound around the teeth 22 and the teeth covering portion 32. Furthermore, an insulating sheet 40 is placed between the coil 13 around which the wire 13a is wound and the core portion 20 surrounding the slot 27 in which the coil 13 is housed, thereby electrically insulating the core portion 20 and the coil 13.

Next, as shown in the example in Figure 8B, the right coil insulation portion 41 and the left coil insulation portion 41 are bent inward, so that the coil insulation portions 41 cover the coil 13. This forms the segment 12. In this way, as shown in the example in Figure 1, the yoke portions 21 of the nine segments 12 are fixed by welding or other means to create the stator 10. In this stator 10, as shown in the example in Figure 2, the coil insulation portions 41 are interposed between the coils 13 in adjacent segments 12, thus electrically insulating the coils 13 from each other.

(Embodiment 2)
The electric motor 14 according to Embodiment 2 of the present disclosure, as shown in the example in Figure 2, includes a rotor 15 and a housing 16 in addition to the stator 10 according to Embodiment 1. The housing 16 houses the stator 10 and the rotor 15 and is fixed to the stator 10. The rotor 15 has a cylindrical rotating core 15a and a cylindrical rotating shaft 15b. The rotating core 15a is made up of multiple steel plates stacked vertically and fixed by rivets, with permanent magnets embedded inside. The rotating shaft 15b is inserted into the central hole of the rotating core 15a and fixed to the rotating core 15a. The rotor 15 is arranged coaxially with the stator 10 inside the stator 10 and is supported by the housing 16 via bearings so as to be rotatable relative to the stator 10. The outer circumferential surface of the rotor 15 faces the inner circumferential surface of the stator 10 at a distance. An electric motor is an example of the electric motor 14. The stator 10 of the electric motor 14 facilitates the attachment of the insulating sheet 40 to the core portion 20 of the core 18, enabling automated manufacturing. This allows for increased manufacturing efficiency for the electric motor 14.

(Embodiment 3)
The application device 17 according to Embodiment 3 of this disclosure, as shown in the example in Figure 11, has a built-in electric motor 14 and is driven by the electric motor 14. The application device 17 is, as an example, a refrigerant compressor. This refrigerant compressor is provided, for example, in refrigeration equipment and air conditioning equipment. More specifically, examples of equipment equipped with a refrigerant compressor include refrigerators, freezers, air conditioners, display cases, and vending machines. In addition to refrigerant compressors, various other devices such as blowers, pumps, and drive sources for vehicles can also be exemplified as application devices 17. The stator 10 of the electric motor 14 in the application device 17 facilitates the attachment of the insulating sheet 40 to the core portion 20 of the core 18, enabling automated manufacturing. Therefore, the manufacturing efficiency of the application device 17 can be improved.

Furthermore, many improvements and other embodiments of the disclosure will be apparent to those skilled in the art from the above description. Therefore, the above description should be interpreted as illustrative only and is provided for the purpose of teaching those skilled in the art the best mode of carrying out the disclosure. The details of its structure and/or function can be substantially modified without departing from the spirit of the disclosure.

(Other embodiments)
(Note)
Based on the above description of embodiments, the following technologies are disclosed.
The first technology is a stator comprising a cylindrical yoke with a plurality of yoke portions connected together, a core having teeth extending radially inward from the inner surface of the yoke portion toward the axis of the yoke, a coil with wire wound around the teeth, a pair of insulators covering both end faces of the core in an axial direction parallel to the axis, and an insulating sheet insulating the core and the coil, wherein the insulating sheet has a teeth insulating portion covering the side surface of the teeth parallel to the axial direction, a yoke insulating portion with one end connected to the outer end of the teeth insulating portion in the radial direction and covering the inner surface of the yoke portion, a pair of extensions extending from the yoke insulating portion in one and the other axial direction respectively, and a bent portion extending from the extension and bending outward opposite to the radial inward direction, and the insulator has a recess that is recessed from its inner surface and into which the bent portion is fitted.

In this configuration, the insulating sheet is attached to the core and insulator by first attaching the insulator to the core, and then fitting the bent portion of the insulating sheet into the recessed area on the inner surface of the insulator. This simplifies the attachment of the insulating sheet to the core, enabling automated processing. Furthermore, since the recessed area and bent portion do not protrude from the inner surface of the insulator, the wire can be easily wrapped around the teeth.

The second technology is a stator in the first technology, wherein the bent portion extends from the extension portion in a direction away from the teeth in an intersecting direction that intersects the axial and radial directions, and is bent from the extension portion such that its tip is located radially outward from its base in the intersecting direction, and the recess is formed by a locking surface that engages the tip of the bent portion in the intersecting direction. With this configuration, the locking surface at the tip of the bent portion prevents the insulating sheet from separating from the teeth of the core. Therefore, the attachment of the insulating sheet to the core is facilitated, and automation by machine becomes possible. Furthermore, the wire can be easily wound around the teeth without using a jig to fix the insulating sheet to the core.

The third technology is a stator in the first or second technology in which the recess is formed by an inclined surface that slopes from the inner surface of the insulator such that it slopes outward in the radial direction as it moves away from the teeth in an intersecting direction that intersects the axial and radial directions. With this configuration, the insulator is provided with a recess for fitting the bent portion, while ensuring the thickness of the insulator in the radial direction. Therefore, the reduction in the strength of the insulator due to the recess can be reduced.

The fourth technology is a stator according to any of the first to third technologies, wherein the core is provided so as to sandwich the teeth between itself and the yoke portion in the radial direction and has a wide portion wider than the width of the teeth in an intersecting direction with respect to the axial direction and the radial direction; the insulator has a wide covering portion that covers the end face of the wide portion and a protruding portion that protrudes from the wide covering portion along the end of the wide portion in the intersecting direction; and the insulating sheet has a wide insulating portion at one end connected to the inner end of the teeth insulating portion in the radial direction and covering the outer surface of the wide portion, and the wide insulating portion has a locking end at the other end, away from the teeth insulating portion in an intersecting direction with respect to the axial direction and the radial direction, that engages with the protruding portion.

In this configuration, the locking end of the wide insulating section is locked to the protruding section, and the wide insulating section is rotated around this locking end to press against the wide section. Furthermore, the teeth insulating section, connected to the wide insulating section, is rotated around its inner end to press against the teeth. Finally, the yoke insulating section is rotated around its outer end to press against the yoke section. In this way, by pressing the insulating sheet against the wide section, teeth, and yoke section of the core in that order, the core can be covered with the insulating sheet, thus facilitating the attachment of the insulating sheet to the core and enabling automated installation by machine.

The fifth technology is a stator in the fourth technology, wherein the wide insulating portion has an extended insulating portion extending from the locking end in a direction intersecting the axial direction, and the extended insulating portion protrudes from between a pair of protrusions in the axial direction. With this configuration, by having the extended insulating portion protrude between the pair of protrusions, the extended insulating portion is locked by the pair of protrusions in the axial direction, thus allowing the insulating sheet to be positioned on the core in the axial direction. Therefore, the attachment of the insulating sheet to the core is facilitated, and automation by machine becomes possible.

The sixth technology is a stator according to any of the first to fifth technologies, wherein the insulating sheet has a coil insulating portion connected to the other end of the yoke insulating portion, which is further from the teeth than one end of the yoke insulating portion in a direction intersecting the axial and radial directions, and which covers the coil, and a fold extending in the axial direction between the yoke insulating portion and the coil insulating portion.

With this configuration, when winding the wire around the teeth with the insulating sheet attached, bending the coil insulating portion radially outward relative to the yoke insulating portion at the fold of the insulating sheet makes it less likely for the wire to come into contact with the coil insulating portion. Therefore, winding the wire around the teeth becomes easier, and the assembly of the stator can be automated.

The seventh technology is a stator according to any of the first to sixth technologies, wherein the insulating sheet has a symmetrical shape with respect to a plane perpendicular to the axial direction. With this configuration, one type of insulating sheet can be attached to both one side and the other side of the teeth in the intersecting direction by inverting it with respect to a plane perpendicular to the axial direction. Therefore, it is not necessary to use separate insulating sheets for one side and the other side of the teeth, reducing the number of insulating sheet types to one and lowering the cost of the stator.

The eighth technology is an electric motor equipped with one of the first to seventh stators. This configuration facilitates the attachment of an insulating sheet to the core of the electric motor's stator, enabling automated manufacturing. Therefore, the manufacturing efficiency of electric motors equipped with this stator can be improved.

The ninth technology is an application device equipped with the electric motor of the eighth technology. This configuration facilitates the attachment of the insulating sheet to the core of the stator of the application device, enabling automated manufacturing. Therefore, the manufacturing efficiency of application devices equipped with this stator can be improved.

10: Stator 11: Yoke 11a: Shaft 13: Coil 13a: Wire 14: Motor 17: Application equipment 18: Core 21: Yoke section 22: Teeth 23: Wide section 30: Insulator 33: Wide covering section 34: Protruding section 37: First recess (recess)
37a: First slope (slope)
37b: First locking surface (locking surface)
40: Insulating sheet 41: Coil insulating section 41a: Fold 42: Yoke insulating section 43: Teeth insulating section 44: Wide insulating section 44a: Right end (locking end)
45: Extended insulating part 46: Extended part 47: Bent part

Claims (12)

A cylindrical yoke in which multiple yoke sections are connected, and a core having teeth that extend radially inward from the inner surface of the yoke section toward the axis of the yoke,
A coil with wire wrapped around the aforementioned teeth,
The core comprises a pair of insulators that cover both end faces in the axial direction parallel to the axis,
The system includes an insulating sheet that insulates the core and the coil,
The aforementioned insulating sheet is
A tooth insulating portion covering the side surface of the tooth parallel to the axial direction,
A yoke insulating portion, one end of which is connected to the outer end of the tooth insulating portion in the radial direction and which covers the inner surface of the yoke portion,
A pair of extensions are provided, extending from the yoke insulating portion in one and the other axial directions, respectively, without any folds.
It has a pair of bent portions that extend from the pair of extensions and bend outward in the opposite direction to the radially inward direction,
The insulator has a recess that is recessed from its inner surface and into which the bent portion is fitted.
stator. A cylindrical yoke in which multiple yoke sections are connected, and a core having teeth that extend radially inward from the inner surface of the yoke section toward the axis of the yoke,
A coil with wire wrapped around the aforementioned teeth,
The core comprises a pair of insulators that cover both end faces in the axial direction parallel to the axis,
The system includes an insulating sheet that insulates the core and the coil,
The aforementioned insulating sheet is
A tooth insulating portion covering the side surface of the tooth parallel to the axial direction,
A yoke insulating portion, one end of which is connected to the outer end of the tooth insulating portion in the radial direction and which covers the inner surface of the yoke portion,
A pair of extensions extending from the yoke insulating portion, one in the axial direction and the other in the axial direction,
It has a pair of bent portions that extend from the pair of extensions and bend outward in the opposite direction to the radially inward direction,
A space is formed between the yoke insulating portion and the bent portion.
The insulator has a recess that is recessed from its inner surface and into which the bent portion is fitted.
stator. A cylindrical yoke in which multiple yoke sections are connected, and a core having teeth that extend radially inward from the inner surface of the yoke section toward the axis of the yoke,
A coil with wire wrapped around the aforementioned teeth,
The core comprises a pair of insulators that cover both end faces in the axial direction parallel to the axis,
The system includes an insulating sheet that insulates the core and the coil,
The aforementioned insulating sheet is
A tooth insulating portion covering the side surface of the tooth parallel to the axial direction,
A yoke insulating portion, one end of which is connected to the outer end of the tooth insulating portion in the radial direction and which covers the inner surface of the yoke portion,
A pair of extensions extending from the yoke insulating portion, one in the axial direction and the other in the axial direction,
It has a pair of bent portions that extend from the pair of extensions and bend outward in the opposite direction to the radially inward direction,
The insulator has a recess that is recessed from its inner surface and into which the bent portion is fitted,
The bent portion extends from the extension portion in a direction away from the teeth in an intersecting direction that intersects the axial direction and the radial direction, and is bent from the extension portion such that its tip is located radially outward from its base in the intersecting direction.
The recess is formed by a locking surface that locks the tip of the bent portion in the intersecting direction.
stator. A cylindrical yoke in which multiple yoke sections are connected, and a core having teeth that extend radially inward from the inner surface of the yoke section toward the axis of the yoke,
A coil with wire wrapped around the aforementioned teeth,
The core comprises a pair of insulators that cover both end faces in the axial direction parallel to the axis,
The system includes an insulating sheet that insulates the core and the coil,
The aforementioned insulating sheet is
A tooth insulating portion covering the side surface of the tooth parallel to the axial direction,
A yoke insulating portion, one end of which is connected to the outer end of the tooth insulating portion in the radial direction and which covers the inner surface of the yoke portion,
A pair of extensions extending from the yoke insulating portion, one in the axial direction and the other in the axial direction,
It has a pair of bent portions that extend from the pair of extensions and bend outward in the opposite direction to the radially inward direction,
The insulator has a recess that is recessed from its inner surface and into which the bent portion is fitted.
stator. The bent portion extends from the extension portion in a direction away from the teeth in an intersecting direction that intersects the axial direction and the radial direction, and is bent from the extension portion such that its tip is located radially outward from its base in the intersecting direction.
The recess is formed by a locking surface that locks the tip of the bent portion in the intersecting direction.
A stator according to any one of claims 2 to 4. The recess is formed by an inclined surface that slopes from the inner surface of the insulator such that it slopes outward in the radial direction as it moves away from the teeth in an intersecting direction that intersects the axial direction and the radial direction.
A stator according to any one of claims 1 to 4. The core is provided such that it sandwiches the teeth between itself and the yoke portion in the radial direction and has a wide portion that is wider than the width of the teeth in the axial direction and in the intersecting direction that intersects the radial direction.
The aforementioned insulator is
A wide covering portion that covers the end face of the wide portion,
It has a protruding portion that extends from the wide covering portion along the edge of the wide portion in the intersecting direction,
The insulating sheet has a wide insulating portion, one end of which is connected to the inner end of the teeth insulating portion in the radial direction and which covers the outer surface of the wide portion.
The wide insulating portion has a locking end that is at the other end, away from the teeth insulating portion in an intersecting direction that intersects the axial and radial directions, and that engages with the protruding portion.
A stator according to any one of claims 1 to 4. The wide insulating portion has an extended insulating portion extending from the locking end in a direction intersecting the axial direction,
The extended insulating portion protrudes between the pair of protrusions in the axial direction.
The stator according to claim 7. The aforementioned insulating sheet is
A coil insulating portion is connected to the other end of the yoke insulating portion, which is further from the teeth than one end of the yoke insulating portion, in an intersecting direction that intersects the axial direction and the radial direction, and covers the coil.
The yoke insulating portion and the coil insulating portion have a fold extending in the axial direction,
A stator according to any one of claims 1 to 4. The insulating sheet has a shape that is symmetrical with respect to a plane perpendicular to the axial direction.
A stator according to any one of claims 1 to 4. An electric motor comprising a stator as described in any one of claims 1 to 4. An application device comprising the electric motor described in claim 11.