JPH0759288A - Stator of brushless motor - Google Patents

Abstract

PURPOSE:To obtain the stator of a brushless motor with a high authenticity and reliability of connection between a stator coil winding terminal and a conductive pattern by forming a conductive pattern with a metal plate which is rigid and can be formed three-dimensionally and then reducing component cost and assembly cost. CONSTITUTION:A stator is fixed to a substrate 5 and the substrate 5 has a conductive pattern 3 according to the forming machining of a metal plate. The conductive pattern 3 has a cut and raised part 6 and then a stator coil winding terminal 10 is connected to the cut and raised part 6 or a terminal plate where the coil winding terminal 10 is connected is pressed and retained. A groove-shaped part is formed at the conductive pattern 3 or groove-shaped parts 7 and 8 are formed at the cut and raised part 6 and then the coil winding terminal 10 may be held by the groove-shaped part or the terminal plate may be pressed and retained.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a stator of a brushless motor, and more particularly to a structure of a base and a conductive pattern and a stator winding terminal treatment structure.

[0002]

18 to 25 show examples of conventional brushless motors. 18 to 22, the brushless motor has a stator set 75 and a rotor set 80. The stator set 75 has a stator core 77 and a stator winding 78 wound around a plurality of salient poles formed on the stator core 77, and a coupling member 79 such as a screw is provided under the interposition of the core holder 76. The stator core 77 is fixed to the stator substrate 61. The bearing holder 70 is fixed by sandwiching the flange portion of the bearing holder 70 between the stator substrate 61 and the inner peripheral edge portion of the stator core 77. A bearing 72 is provided on the inner peripheral side of the bearing holder 70.
The shaft 73 is rotatably supported by the bearing 72. The rotor set 80 is integrally connected to the shaft 73.

As shown in FIG. 21, the stator substrate 61 has a base 62 made of an iron plate or the like, an insulating layer 63 covering one surface of the base 62, and a predetermined pattern of copper foil or the like on the insulating layer 63. And the conductor layer 64 formed on the
4 and a resist layer 65 covering the insulating layer 63. A stator winding 78 is connected to the conductor layer 64, and by energizing the stator winding 78 through the conductor layer 64, rotational torque is generated by electromagnetic action between each salient pole of the stator core 77 and the drive magnet 82 of the rotor set 80. Then
The rotor set 80 is rotationally driven.

The stator substrate 61 is generally manufactured by the following procedure. The insulating layer 63 is formed on the base body 62 by pressure bonding or painting. The conductor layer 64 is formed on the entire surface of the insulating layer 63 by pressure bonding or plating of a metal foil. The conductor layer 64 is formed into a predetermined circuit pattern by etching. Secondary processing such as drilling is performed if necessary.

23 to 25 show an example of connection of terminals of the stator winding 78 to the conductor layer 64 of the stator substrate 61. In the example of FIG. 23, a terminal plate 68 having an inverted U-shaped cut / bent portion 69 is embedded in the core holder 76, and the terminal plate 68 has the cut / bent portion 69 at the stator winding terminal 1.
0 is hooked, the stator winding terminal 10 and the terminal plate 68 are electrically connected by welding, fusing or the like, and the stator set 75 is positioned on the stator substrate 61 to form a predetermined pattern. The conductor layer 64
In the example in which the tip of the terminal plate 68 is opposed to the solder land 67, the solder land 67 and the terminal plate 68 are soldered by an appropriate means, and the stator winding 78 and the conductor layer 64 are connected. is there.

In the example of FIG. 24, the stator core 77 is fixed to the stator substrate with the interposition of the core holder 76 as described with reference to FIGS. 18, 19 and 22, and the end 10 of the stator winding 78 is fixed. The connecting wire is passed through the cutout portion of the core holder 76, and the stator winding terminal 10 is soldered 66 to the soldering land 67 of the conductor layer 64.
Are connected by. Actual Kaihei 2-104746
The one described in the gazette corresponds to this example.

The example of FIG. 25 is an example of connection of an air-core coil 85 formed by winding a wire having a rectangular cross section.
Are positioned so that the winding start portion 86 and the winding end portion 87 of the air-core coil 85 are adjacent to the soldering lands 67 of the conductor layer 64, and the winding start portion 86, the soldering land 67, and the winding end portion 87 are arranged. The soldering lands 67 are connected to each other with solder 66.

[0008]

According to the conventional connecting structure of the stator winding and the conductor layer of the circuit board described above,
There are the following problems. According to a general connection structure in which the stator winding ends are connected to the soldering lands by soldering, the circuit board and its peripheral components must have heat resistance sufficient to withstand the heat of soldering. Cost increases and the soldering quality varies greatly. When the stator winding ends are connected by welding, the insulation characteristics of the circuit board and the conductor layer are likely to be impaired. Since the conductor layer is mainly formed into a predetermined pattern and a thin flat surface by etching, it is necessary to pull down the stator winding terminal to the solder land of the conductor layer. However, it is difficult to automate this pulling down work, and it is difficult to downsize the motor because a work space for pulling down is required. An inexpensive method is also considered in which the stator winding ends are brought into direct contact with the conductor layer or the terminal plate to which the stator winding ends are connected is pressed to make contact, but this method impairs the connection due to vibration or the like. It is easy to get caught.

The present invention has been made in order to solve the above-mentioned problems of the prior art. By forming a conductive pattern with a metal plate which has rigidity and is three-dimensionally moldable, the cost of parts and the cost can be reduced. Assembly cost can be reduced,
Another object of the present invention is to provide a stator for a brushless motor, which has high reliability and reliability of connection between the stator winding terminal and the conductive pattern.

[0010]

In order to achieve the above object, the present invention has a basic structure in which a base body for fixing a stator has a conductive pattern formed by a metal plate forming process. A raised portion is provided and a stator winding end is connected to the cut and raised portion, or a terminal plate to which the stator winding end is connected is held in pressure contact with the cut and raised portion. A groove portion may be provided in the conductive pattern, and the stator winding terminal may be connected to the groove portion.
Furthermore, a groove-like portion is provided in the cut-and-raised portion of the conductive pattern,
The grooved portion may sandwich the stator winding terminal, or the terminal plate to which the stator winding terminal is connected may be pressed and held. A window hole may be provided in the conductive pattern, and the terminal plate may be pressed and held in the window hole.

[0011]

The conductive pattern formed by forming the metal plate has rigidity by itself, so that it can be formed into a three-dimensional shape. Further, a part of the base body holding the conductive pattern is removed to form the conductive pattern. Even if it has a bridge shape, it can retain its shape. Therefore, a part of the conductive pattern is cut and raised, the stator winding is connected to the cut and raised portion, or the terminal plate to which the stator winding is connected is pressed and held. It is also possible to form a groove-shaped portion in the bridge-shaped portion of the conductive pattern and connect the stator winding to the groove-shaped portion. It is also possible to form a groove-shaped portion in the cut-and-raised portion, and the stator winding or the terminal plate can be connected to this groove-shaped portion.

[0012]

Embodiments of the brushless motor stator according to the present invention will now be described with reference to FIGS. 1 to 3, the substrate 1 is formed into a desired shape by pressing or the like. The material of the substrate 1 may be a conductive material such as iron or an insulating material such as phenol resin or nylon resin.
An insulating layer 2 is provided on one surface of the substrate 1. A conductive pattern 3 is also fixed to the substrate 1 via the insulating layer 2. The conductive pattern 3 is manufactured by punching and bending a thin plate made of, for example, a copper alloy into a desired shape by press working. These substrate 1, insulating layer 2,
The conductive pattern 3 constitutes the base body 5 of the stator of the brushless motor.

A cut-and-raised portion 6 extending in a direction perpendicular to the substrate 1 is formed by bending a part of the conductive pattern 3.
Are formed. The cut-and-raised portion 6 is formed with a V-shaped groove-shaped portion 7 from the tip side thereof, and the bottom portion of the groove-shaped portion 7 is further connected to a parallel groove-shaped portion 8 having a narrow ridge. The stator winding terminal 10 is received from the groove portion 7, and the winding terminal 10 is further sandwiched by the groove portion 8. The winding terminal 10 includes a core wire 11 made of a copper wire or the like and an insulating layer 12 covering the outer circumference of the core wire 11. When the diameter of the core wire 11 is φd, the width of the groove portion 8 is the same as or slightly smaller than φd. Therefore, when the winding terminal 10 is sandwiched by the groove portion 8, the insulating layer 12 is cut off at the edge portion of the groove portion 8 and the core wire 11 contacts the edge portion of the groove portion 8, The terminal 10 is electrically connected to the predetermined conductive pattern 3 via the cut-and-raised portion 6. In the example shown on the right side of FIG. 1, the cut-and-raised portion 6 is formed on the side portion in the longitudinal direction of the conductive pattern 3.
In the example shown on the left side of FIG. 3 and the example shown in FIG.

FIG. 2 shows a specific example in which the above winding terminal connection structure is applied to a brushless motor. The structure of the stator 15 of the brushless motor is similar to that of the conventional example described above. That is, the stator 15 has a stator core 17, a stator winding 18 wound around its salient poles, and a core holder 16. The cut-out portion of the core holder 16 is provided with the actual flat plate 2
In the same manner as the one described in Japanese Patent Laid-Open No. 104746, the terminal 10 of the stator winding 18 is stretched as a crossover wire, and when the stator 15 is positioned on the base body 5, the winding terminal 10 is stretched. The winding terminal 10 is received from the groove-shaped portion 7 of the cut-and-raised portion 6 and sandwiched in the groove-shaped portion 8, and the winding terminal 10 is electrically connected to the predetermined conductive pattern 3 through the cut-and-raised portion 6 as described above. It is supposed to be done.

As described above, since the conductive pattern 3 is formed by molding the metal plate by pressing or the like, the conductive pattern 3 has rigidity by itself and can be molded three-dimensionally. Therefore, a cut-and-raised portion 6 is formed in a part of the conductive pattern 3, groove-shaped portions 7 and 8 are formed in the cut-and-raised portion 6, and the stator winding terminal 10 is sandwiched in the groove-shaped portions 7 and 8. The winding end 10 is connected to the conductive pattern 3. Therefore, it is not necessary to connect the winding terminal and the conductive pattern by soldering, welding or the like as in the conventional case, the heat resistance of the base 5 and the components around it is not required, and the cost of the components can be reduced. In addition, the quality can be stabilized, and the deterioration of the insulating property between the substrate 1 and the conductive pattern 3 can be prevented.

Further, by forming a cut-and-raised portion 6 in a part of the conductive pattern 3 to make it three-dimensional, the height position of the routing surface of the winding terminal 10 and the winding terminal 10 formed by the groove-shaped portions 7 and 8. Since it can be matched with the height position of the winding end, it is not necessary to pull down the winding terminal as in the conventional method, and the wiring work can be automated and the space for pulling down the winding terminal can be achieved. Is unnecessary, and the brushless motor can be downsized. Further, since the winding terminal 10 is sandwiched by the groove-shaped portions 7 and 8, the connection is not damaged by vibration or the like.

Next, various modifications of the present invention will be described. In the embodiment shown in FIG. 4, the engaging portion 19 is formed by cutting and raising in the cut-and-raised portion 6 formed in a part of the conductive pattern 3, and after the stator winding terminal 10 is engaged with the engaging portion 19, The locking portion 19 is further bent to wind the winding end 10
The winding end 10 is sandwiched between the main body of the cut-and-raised portion 6 and the locking portion 19 to electrically connect the winding terminal 10 to the conductive pattern 3.

In the embodiment shown in FIG. 5, a V-shaped groove 20 is formed in the cut-and-raised portion 6 formed in a part of the conductive pattern 3, and the groove 20 is formed on both sides of the groove 20 near the open end. The winding ends 10 are formed by forming protrusions 6a, 6a facing each other, and forming notches 6b, 6b at positions corresponding to the bottom of the groove-like portion 20 on both sides of the outer edge of the cut-and-raised portion 6.
The cut-and-raised portion 6 in a state of being received in the groove-like portion 20, the both sides of the cut-and-raised portion 6 are pressed above the cuts 6b, 6b to form the protrusion 6
The width of the grooved portion 20 is narrowed until the a and 6a come into contact with each other, and the winding terminal 10 is sandwiched in the grooved portion 20 and electrically connected. When the width of the groove-shaped portion 20 when the protrusions 6a, 6a are in contact with each other is X, X is set to be equal to or slightly smaller than the diameter of the core wire of the winding terminal 10.

In the embodiment shown in FIG. 6, the cut-and-raised portion 6 and the groove-shaped portions 7 and 8 similar to those in the examples shown in FIGS. 1 to 3 are formed,
The winding terminal 10 is sandwiched between the groove-shaped portions 7 and 8, and the winding terminal 10 is wound around the cut-and-raised portion 6.

In each of the embodiments described above, the winding end portion 10 is directly connected to the cut-and-raised portion 6, but the winding end portion 10 is cut-and-raised with the interposition of the terminal plate. You may connect to the part 6. FIG. 7 shows an example thereof. The winding terminal 10 is locked to the locking portion 24 formed by cutting and bending the terminal plate 23 and connected by welding or the like, and the groove 25 formed in the terminal plate 23 is formed into a conductive pattern. The groove-like portion 22 formed in the cut-and-raised portion 6 of FIG. 3 is pressed and held, and the cut-and-raised portion 6 and the terminal plate 23 are connected in a cross shape when viewed from above. Here, the plate thickness of the conductive pattern 3 is X ₁ , the width of the groove 25 of the terminal plate 23 is X ₂ , and the groove-shaped portion 2 of the cut-and-raised portion 6 is
When the width of 2 is X ₃ and the thickness of the terminal board 23 is X ₄ , X ₁
Is slightly larger than X ₂ and X ₃ is slightly smaller than X ₄ . Therefore, the groove 25 of the terminal plate 23 forcibly grips the cut-and-raised portion 6, the groove-like portion 22 of the cut-and-raised portion 6 forcibly grips the terminal plate 23, and the terminal plate 23 is cut-and-raised. 6 is firmly and surely held and electrically connected. In this way, the winding terminal 10 is electrically connected to the conductive pattern 3 via the terminal plate 23.

According to the embodiment shown in FIG. 7, the terminal board 23 is required, but it is not necessary to connect the winding terminal and the conductive pattern by soldering, welding or the like as in the above-mentioned embodiments. The heat resistance of the base 5 and the components around it is not necessary, the cost of the components can be reduced and the quality can be stabilized, and the deterioration of the insulation characteristics between the substrate 1 and the conductive pattern 3 can be prevented. can do. In addition, the same effect as that of the above-described embodiment is obtained.

As another example of holding the winding ends in pressure contact with the cut-and-raised portion of the conductive pattern under the interposition of the terminal plate, FIG.
There is also an example as shown in. In the example shown in FIG. 8, the terminal plate 25 is bent and formed in a corrugated shape so as to have elasticity, and the terminal plate 25 is elastically fitted into the groove-like portion 28 formed in the cut-and-raised portion 6 of the conductive pattern 3 to form the terminal. The plate 25 is held in pressure contact with the cut-and-raised portion 6. Protrusions 29, 29 are formed facing each other near the open end of the groove portion 28 to prevent the terminal plate 25 from falling off. Contrary to the example of FIG. 8, the cut-and-raised part of the conductive pattern may be elastically fitted into the groove-shaped part formed in the terminal plate.

In all of the embodiments described so far, the cut and raised portions are formed in the conductive pattern, but the intended purpose can be achieved without forming the cut and raised portions. An example thereof is shown in FIGS. In FIG.
Reference numeral 1 denotes a substrate, 2 denotes an insulating layer, and 3 denotes a conductive pattern. The substrate 1, the insulating layer 2 and the conductive pattern 3 constitute a base body 5 of a brushless motor stator. A rectangular window hole 31 is formed in the substrate 1, and a rectangular window hole 32 is formed in the insulating layer 2 at a position overlapping with the window hole 31, and the conductive pattern 3 crosses over these window holes 31 and 32. The conductive pattern 3 has a pair of groove portions 34, 34 formed from one side edge portion on the window holes 31, 32 to form a triangular protrusion 33 therebetween. The stator winding terminal 10 is provided in the pair of groove-shaped portions 34, 34.
Are pulled through, hooked on the protrusion 33, and electrically connected. The winding terminal 10 may have the insulating layer of the hooking portion removed in advance. The window holes 31 and 32 of the substrate 1 and the insulating layer 2 serve as an escape for the winding terminal 10 that wraps around the lower side of the conductive pattern 3.

The embodiment shown in FIG. 10 is an example in which a terminal plate is pressed and held without providing a cut-and-raised portion in the conductive pattern 3, and a rectangular window hole 31 is formed in the substrate 1 and the conductive pattern 3 is formed.
A rectangular window hole 37 is formed at a position overlapping with the window hole 31, while the terminal plate 2 to which the winding terminal 10 is electrically connected is formed.
A protrusion 35 is formed at the lower end of the protrusion 3.
The winding terminal 10 is connected to the conductive pattern 3 by pressing and holding it in the window hole 37 of the conductive pattern 3. The window hole 31 of the substrate 1 is an escape for the protrusion 35. Although the insulating layer 2 is not provided with a window hole for escaping the protruding portion 35, when the protruding portion 35 is held in pressure contact with the window hole 37 of the conductive pattern 3, the insulating layer 2 is broken by the protruding portion 35 and protrudes. The portion 35 enters the window hole 31.
Of course, the insulating layer 2 may be provided with a window hole.

As is clear from each of the embodiments described above, the present invention does not use a conventionally used printed circuit board, but fixes a conductive pattern formed by molding a metal plate to the printed circuit board. It has the same function as. According to the printed circuit board, the base body is limited to a flat body and cannot be drawn or bent. However, according to the present invention using the conductive pattern as described above, the base body is drawn or bent. It does not matter if it is a three-dimensional object. Hereinafter, various examples utilizing such characteristics of the present invention will be described.

In the example shown in FIG. 11, when connecting the soldering lands 38, 38 of the pair of conductive patterns 3, 3 with the jumper chip 40, the board is cut and raised to connect the pair of soldering lands 38, 38. In, a pair of bent portions 39, 39 are formed, and both sides of the jumper chip 40 are pressed by the bent portions 39, 39 for positioning. When the jumper chip 40 is soldered to the soldering lands 38, 38, the jumper chip 40, which is a minute electric component, may be biased or tilted due to the surface tension of the melted solder, but as in the example of FIG. By pressing both sides of the jumper chip 40 with the bent portions 39, 39, it is possible to prevent the jumper chip 40 from being offset or tilted.

The embodiment shown in FIG. 12 is substantially the same as the embodiment shown in FIG. 11, and the bent portion 3 of the embodiment shown in FIG.
Instead of 9, 39, a cylindrical pillar 4 made by drawing a substrate.
2, 42 are formed, and both sides of the jumper chip 40 are pressed and positioned by the columns 42, 42. It should be noted that the same effect can be obtained when a resistor, a capacitor, or other appropriate electric component is used instead of the jumper chip 40 in the examples of FIGS. 11 and 12.

In the embodiment shown in FIG. 13, a cylindrical bearing holder portion 43 and an appropriate number of core holder portions 44 are formed on a substrate 1 made of an iron plate or the like by drawing.
A bearing 45 is fitted on the inner peripheral side of the bearing holder portion 43, and a shaft 46 is rotatably supported by the bearing 45. A stator core 47 is provided on the outer peripheral side of the bearing holder portion 43.
The center hole of is fitted. The stator core 47 is placed on the core holder portion 44, and the height position of the stator core 47 is regulated. The screw 48 inserted into the hole of the stator core 47 is screwed into the core holder portion 44,
The stator core 47 is screwed to the substrate 1.

As described above, according to the present invention using the conductive pattern formed by the forming process of the metal plate, the substrate can be three-dimensionally formed by performing the drawing process or the bending process. The substrate 1 itself can be used as the bearing holder portion 43 or the core holder portion 44 as in the embodiment shown in (1), and therefore, it is not necessary to prepare the bearing holder, the core holder and the like as separate parts, and the number of parts is small. It is possible to obtain a stator of a brushless motor with low component cost.

In the embodiment shown in FIG. 14, a part of the substrate 1 constituting the base body 5 is formed into a truncated cone shape and is used as a core holder portion 1a. The stator core 17 is placed on the core holder portion 1a and screwed. It was done. According to the embodiment shown in FIG. 14 and the embodiment shown in FIG. 13, the stator core is raised from the base body 5 by a predetermined dimension and fixed by the core holder portion of the substrate 1 itself. Therefore, as shown in FIG. 14 and as shown in FIGS. 1 to 3, the winding terminal 10 may be connected to the groove-shaped portion formed in the cut-and-raised portion 6 of the conductive pattern 3. For example, it is possible to match the routing position of the winding ends up to the respective layer stator windings 18 and the position of the groove-shaped portion of the cut-and-raised portion 6. Therefore, it is not necessary to pull down the winding terminal 10 to the position of the conductive pattern 3 of the base body 5, the connection work is extremely simple, and wiring by an automatic machine is possible.
Since a space for lowering the brush is not required, the brushless motor can be downsized.

15 and 16 show an embodiment in which an air-core coil having a rectangular wire wound is applied to the present invention. 15 and 1
6, an air-core coil 53 formed by winding a rectangular wire in a trapezoidal shape has a winding start portion 54 and a winding end portion 55 on the inner peripheral side and the outer peripheral side of one side of the trapezoid. The distance between the winding start portion 54 and the winding end portion 55 is W ₂ . On the other hand, in the pair of conductive patterns 3 and 3, the cut-and-raised portion 5 is formed at the side edge of each one end.
0, 50 are formed. This cut-and-raised part 50, 5
0 is formed so as to be located in the same vertical plane, and the distance W ₁ between the facing portions of the cut and raised portions 50, 50 is slightly smaller than the above W ₂ . On one conductive pattern 3, a bent portion 52 is formed to avoid contact with one side of the air-core coil 53.

As shown in FIG. 16, the air-core coil 53 is positioned so that the winding start portion 54 and the winding end portion 55 are sandwiched by the cut-and-raised portions 50, 50 of the pair of conductive patterns 3, 3. Will be placed. In this way, the winding start portion 54 and the winding end portion 55 of the air-core coil 53 have the cut-and-raised portions 50,
The air-core coil 53 is connected to the conductive patterns 3 and 3 by contacting 50.

Although various embodiments have been described above, the following various modifications are possible. If the substrate is made of an insulating material, it is not necessary to provide an insulating layer. It suffices that the conductive pattern is fixed to the substrate in an insulating state, and the fixing means is not limited, and adhesion, welding, or other appropriate means may be used. The conductive pattern may be fixed after the insulating layer is fixed or formed on the substrate, or the insulating layer may be fixed on the conductive pattern and then fixed on the substrate. Alternatively, the sheet-like insulating layer may be sandwiched between the substrate and the conductive pattern and fixed at one time by heat welding or the like. After forming the insulating layer on the conductive pattern or the substrate, it may be molded into a desired shape by pressing or the like, or after fixing the substrate and the conductive pattern, punching or bending a part of the substrate or the insulating layer or the conductive pattern. You may. As the conductive pattern, for example, a phosphor bronze plate having a thickness of about 0.1 mm can be used, but a conductive plate material having an arbitrary thickness and material according to required electrical characteristics and mechanical characteristics should be used. You can It is also possible to use a three-dimensional member such as a block material instead of the substrate that constitutes the base body.

In the embodiment shown in FIGS. 1 to 3, the stator winding terminal 10 may be a connecting wire between one pole and another pole as described above, or may be cut to a predetermined length. The post-cut and raised portion 6 may be sandwiched by the groove-shaped portions 7 and 8, or may be cut at a predetermined position after being sandwiched by the groove-shaped portions 7 and 8. The insulating layer of the winding terminal 10 may be removed in advance before it is caught in the groove portions 7 and 8, or may be further plated with solder.

For electrical connection between the winding terminal or the terminal plate and the conductive pattern, welding, winding, etc. may be used instead of pressure welding or pinching, or welding, winding, etc. may be used for pressure welding or pinching. May be added. By doing so, the reliability of the electrical connection is increased, and the winding end or the terminal plate can be prevented from falling off due to vibration or the like. Furthermore, an antioxidant or the like may be applied to the connecting portion. The connection portion may be soldered to prevent corrosion of the connection portion.

As already described, the stator winding may be an air-core coil, and the air-core coil may be a rectangular wire, a round wire or a metal thin film. .

A resist layer for ensuring insulation from other electric parts may be provided on the upper surface of the conductive pattern by, for example, painting. The cut-and-raised part of the conductive pattern is penetrated from the window hole of the substrate to the back side of the substrate in an insulated state
A winding terminal may be connected to the cut-and-raised portion on the back surface side of the substrate.

If the structure of the present invention is applied to the circuit board of the motor with a brush, the brush can be directly fixed to the cut and raised portion of the conductive pattern. The conductive patterns may be provided on both front and back surfaces of the substrate. Further, one side of the board may have the same structure as a conventional circuit board, and the other side may have the structure of the present invention.

[0039]

According to the present invention, since the conductive pattern is formed of a metal plate which is rigid and can be molded three-dimensionally, the cut and raised portion is formed in the conductive pattern as in the invention of claim 1. It is possible to connect the stator winding terminal directly to this cut-and-raised part. As a result, it is possible to provide a stator for a brushless motor that does not require an intervening component such as a terminal plate, has a low component cost, requires a small number of steps for connecting the stator winding ends, and has a low assembly cost. In addition, by matching the height of the drawn surface of the stator winding end with the height of the connection position of the stator winding end to the cut-and-raised part, it is not necessary to pull down the winding end, and the wiring work is automated. In addition, it is possible to reduce the size of the brushless motor because a space for pulling down the winding terminal is not required.

According to the second aspect of the present invention, the terminal winding to which the stator winding terminal is connected is pressed and held at the cut-and-raised portion of the conductive pattern to connect the stator winding terminal to the conductor pattern. It is not necessary to use soldering, welding, etc., and high heat resistant parts are not required, and it is possible to reduce the cost of parts by changing to inexpensive materials.

According to the third aspect of the present invention, by forming the groove-like portion in the conductive pattern and directly connecting the stator winding terminal to the groove-like portion, an intervening component such as a terminal board is not necessary. It is possible to provide a stator of a brushless motor that is low in cost, requires a small number of steps for connecting the stator winding terminals, and is low in assembly cost.

According to a fourth aspect of the present invention, a cut and raised portion is formed in the conductive pattern, a groove portion is formed in the cut and raised portion, and the stator winding terminal is directly connected to the groove portion. , No intervening parts such as terminal boards are required, the parts cost is low, the number of steps required for connecting the stator winding ends is small, and the assembly cost is low. Also, the height of the drawing surface of the stator winding ends and the cut-and-raised part The wiring work can be automated by matching the height of the connection position of the stator winding terminal, and the size of the brushless motor can be reduced by eliminating the space for pulling down the winding terminal.

According to a fifth aspect of the present invention, a cut-and-raised portion is formed in the conductive pattern, a groove-like portion is formed in the cut-and-raised portion, and the terminal plate to which the stator winding terminal is connected is provided with the groove-like portion. By pressing and holding to the conductor pattern, it is not necessary to use soldering or welding to connect the stator winding end to the conductor pattern, high heat resistant parts are not required, and cost can be reduced by changing to cheaper materials Can be achieved.

According to a fifth aspect of the present invention, a window hole is formed in the conductive pattern, and the terminal plate to which the stator winding terminal is connected is pressed and held in the window hole, so that the conductive pattern has the stator winding terminal. It is not necessary to use soldering, welding, or the like for connecting the parts, and high heat resistant parts are not required, and it is possible to reduce the parts cost by changing to an inexpensive material.

According to the first, second, fifth, and sixth aspects of the invention, as shown in FIG. 17, the stator and the base body are assembled by moving the stator in the axial direction. Then, the movement required for assembling connects the end of the stator winding and the conductive pattern, so that the step of connecting the stator winding becomes unnecessary, and the assembling cost can be reduced.

[Brief description of drawings]

FIG. 1 is a front view showing a main part of an embodiment of a stator of a brushless motor according to the present invention.

FIG. 2 is a perspective view of the above embodiment.

FIG. 3 is a perspective view showing a main part of the embodiment.

FIG. 4 is a perspective view showing a main part of another embodiment of the stator of the brushless motor according to the present invention.

FIG. 5 is a front view showing a main part of still another embodiment of the stator of the brushless motor according to the present invention.

FIG. 6 is a perspective view showing a main part of still another embodiment of the stator of the brushless motor according to the present invention.

FIG. 7 is a front view and a side view showing a main part of still another embodiment of the stator of the brushless motor according to the present invention.

FIG. 8 is a front view showing a main part of still another embodiment of the stator of the brushless motor according to the present invention.

9A and 9B are a sectional front view and a plan view showing a main part of still another embodiment of the stator of the brushless motor according to the present invention.

FIG. 10 is a sectional front view showing a main part of still another embodiment of the stator of the brushless motor according to the present invention.

FIG. 11 is a perspective view showing a main part of still another embodiment of the stator of the brushless motor according to the present invention.

FIG. 12 is a perspective view showing a main part of still another embodiment of the stator of the brushless motor according to the present invention.

FIG. 13 is a front sectional view showing still another embodiment of the stator of the brushless motor according to the present invention.

FIG. 14 is a front sectional view showing still another embodiment of the stator of the brushless motor according to the present invention.

FIG. 15 is an exploded perspective view showing a main part of still another embodiment of the stator of the brushless motor according to the present invention.

FIG. 16 is a perspective view of the embodiment.

FIG. 17 is an exploded perspective view showing an embodiment of the stator of the brushless motor according to the present invention.

FIG. 18 is a plan view showing an example of a stator of a conventional brushless motor with a part cut away.

FIG. 19 is a partially sectional front view of the conventional example of the above.

FIG. 20 is a plan view showing a part of the circuit board of the conventional example.

FIG. 21 is an enlarged sectional front view of the same circuit board.

FIG. 22 is a sectional front view of the stator of the conventional brushless motor.

FIG. 23 is a perspective view showing a main part of the conventional example.

FIG. 24 is a perspective view showing a main part of another example of the stator of the conventional brushless motor.

FIG. 25 is a perspective view showing a main part of still another example of the stator of the conventional brushless motor.

[Explanation of symbols]

 3 Conductive Pattern 5 Base 6 Cut-and-raised part 7 Groove-shaped part 8 Groove-shaped part 10 Stator winding terminal 15 Stator 20 Groove-shaped part 23 Terminal plate 25 Terminal plate

Claims (6)

[Claims] 1. A stator of a brushless motor, comprising:
The stator is fixed to the base body, the base body has a conductive pattern formed by forming a metal plate, and the conductive pattern has a cut-and-raised portion, and the stator winding terminal is connected to the cut-and-raised portion. Brushless motor stator. 2. A stator of a brushless motor, comprising:
The stator is fixed to the base body, and the base body has a conductive pattern formed by forming a metal plate, the conductive pattern has a cut-and-raised portion, and the terminal plate to which the stator winding terminal is connected is press-held to the cut-and-raised portion. The stator of the brushless motor is characterized in that 3. A stator of a brushless motor, comprising:
The stator is fixed to the base body, the base body has a conductive pattern formed by forming a metal plate, and the conductive pattern has a groove portion, and the stator winding terminal is connected to the groove portion. Brushless motor stator. 4. A stator of a brushless motor, comprising:
The stator is fixed to the base body, and the base body has a conductive pattern formed by forming a metal plate, the conductive pattern has a cut-and-raised portion, and the cut-and-raised portion has a groove-shaped portion, and the stator winding is provided in the groove-shaped portion. A stator for a brushless motor, wherein the stator winding ends are connected to a conductive pattern by the ends being sandwiched. 5. A stator of a brushless motor, comprising:
The stator is fixed to the base body, the base body has a conductive pattern formed by molding a metal plate, the conductive pattern has a cut-and-raised portion, the cut-and-raised portion has a groove-shaped portion, and a stator winding terminal is connected. A stator of a brushless motor, characterized in that the terminal winding is connected to the conductive pattern by holding the terminal plate in pressure contact with the groove. 6. A stator of a brushless motor, comprising:
The stator is fixed to the base body, the base body has a conductive pattern formed by forming a metal plate, and the conductive pattern has a window hole,
A stator of a brushless motor, wherein a terminal plate to which a stator winding terminal is connected is held in pressure contact with the window hole.