JPH0880002A - Molded motor - Google Patents

Abstract

PURPOSE: To provide a molded motor which dispenses with the welding by uniting each core making use of the printed circuit board when a stator core is formed by abutting a plurality of arc-shaped cores, reduces the man-hour during the manufacturing, and improve the electromagnetic characteristics of the stator core. CONSTITUTION: A stator core 1 is formed by abutting a plurality of half- doughnut shaped cores 1a, 2a where a plurality of half-doughnut shaped flat rolled magnetic steel sheets are laminated. An insulating body 2 is formed of half-doughnut shape, and mounted on each core, and a plurality of pins 38, 39 are projectingly provided on its side, and the respective cores 1a, 2a are annularly united by inserting the respective pins 38, 39 into the holes in the printed circuit board.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molded motor used for driving a blower fan of a home air conditioner.

[Prior art]

Conventionally, as a motor used for a blower fan of a home air conditioner or the like, a DC motor whose speed can be easily adjusted is often adopted because it is necessary to control the amount of blown air in multiple stages.

The DC motor has the advantage that the winding structure can be simpler than that of the induction motor, but on the other hand, the current flowing through the coil (winding) becomes discontinuous, so that electromagnetic vibration is generated. Therefore, in order to reduce the electromagnetic vibration, a stator core and a coil integrally solidified with a thermosetting resin (hereinafter referred to as a mold motor) are often used.

This type of mold motor is disclosed in Japanese Patent Laid-Open No. 5-3.
It is configured as disclosed in Japanese Patent Publication No. 08738 (H02K3 / 46) and the like. FIG. 19 shows a vertical sectional view of a conventional mold motor of this type.

That is, the stator core 101 has an insulator 102
The winding 103 is wound around the yoke of the iron core in a toroidal shape. On the other hand, the holding pin 102A of the insulator 102
A substantially donut-shaped (annular) printed circuit board 112, on which drive circuit components are mounted, is mounted on the printed circuit board 112. The mounting position of the printed circuit board 112 is the winding of the stator core 101 on which the winding 103 is wound. The position is such that it does not contact 103.

Here, the stator core 101 is formed by abutting a pair of semi-donut-shaped (arc-shaped) iron cores each having a plurality of semi-donut-shaped (arc-shaped) electromagnetic steel sheets laminated on each other, and then welding the abutting portions. (Japanese Patent Laid-Open No. 4-3
(See Japanese Patent No. 31434).

Stator core 101 with windings 103 mounted
Is formed as a stator by being housed in a casing 104 integrally molded and solidified with an electrically insulating synthetic resin.

Further, a plurality of lead wires 115 for supplying power or speed detection, a hall element (or hall IC) 108, etc. are attached to the printed board 112,
The lead wire 115 is protected from heat and pressure generated at the time of resin molding by a bush 116 made of synthetic resin fixed to the lead wire 115, or the adhesion with the resin is enhanced.

The bush 116 is usually composed of a pair of bush pieces 118 and 119 which are superposed on each other, and the plurality of lead wires 11 are provided on each superposed surface of the bush pieces.
Corresponding to No. 5, a plurality of grooves 118b and 119b having the same depth and a semicircular cross section are formed. And
The lead wire 115 is held by the plurality of grooves.
In addition, 105 is a rotor, 106 is a rotating shaft, 107 and 111
Is a bearing that supports the rotating shaft 106.

A ring-shaped magnet 109 is attached to the end ring of the rotor 105 so as to face the Hall element 108 of the printed board 112.

Further, the printed circuit board 112 has a plurality of connecting portions on the periphery thereof, and the lead wire of the winding 103 is wound around the connecting portions. Incidentally, there is one in which this connecting portion is formed so as to become wider toward the front side in order to make it easier to wind the lead wire (see Japanese Patent Laid-Open No. 5-308738).

[0012]

However, according to the above configuration, the stator core 101 is formed by abutting a pair of half donut-shaped (arc-shaped) iron cores, each of which is formed by laminating a plurality of half-donut-shaped (arc-shaped) electromagnetic steel sheets. After that, since it is formed by welding the butt portion, there is a problem that welding work is required, not only the number of man-hours increases but also the electromagnetic characteristics of the stator core deteriorate due to heat during welding. .

The present invention has been made in view of the above points,
When forming a stator core by abutting multiple arc-shaped cores, welding is abolished by combining the cores using a printed circuit board, reducing the man-hours required for manufacturing and reducing the electromagnetic force of the stator core. It is an object of the present invention to provide a molded motor that can improve characteristics.

Another object of the present invention is to provide a molded motor capable of preventing a decrease in the winding amount of a coil when the printed circuit board is held by an insulating pin.

[0015]

According to a first aspect of the present invention, there is provided a molded motor including a stator having a stator winding wound thereon, and an annular printed circuit board disposed on a coil end side of the synthetic resin having electrical insulation. In this case, the stator is fixed to each of the iron cores after covering each of a plurality of arc-shaped iron cores formed in an annular shape by abutting with an insulating member molded of synthetic resin. By positioning the iron core by winding the child windings and fitting the pins protruding from the respective insulating members to the coil end side and integrally molded with the insulating members at predetermined positions on the annular printed circuit board. It is formed in a ring shape.

In the above-described molded motor according to a second aspect of the present invention, the diameter of the pin on the abutting portion side of each iron core is made larger than the diameter of the other pins.

According to a third aspect of the present invention, in the molded motor of the first aspect, the stator is composed of a plurality of teeth and a yoke, and the pin located on the tip side of the teeth has a large diameter.
The pin located on the yoke side has a small diameter.

[0018]

According to the mold motor of the invention of claim 1,
By fitting the pins of the insulating member to the predetermined positions on the printed circuit board, it is possible to position multiple arc-shaped iron cores and form an annular stator iron core. It is possible to reduce the man-hours required at the time and improve the electromagnetic characteristics of the stator core.

In addition to the above, in addition to the above, the diameter of the pin on the abutting portion side of each iron core is made larger than the diameters of the other pins. It is possible to increase the binding force of each iron core near the part.

Further, according to the invention of claim 3, in addition to claim 1, the pin located on the tip side of the tooth portion of the stator core has a large diameter, and the pin located on the yoke side has a small diameter. Therefore, the coil winding work can be smoothly performed while maintaining the holding force of the printed circuit board.

[0021]

Embodiments of the present invention will be described below in detail with reference to the drawings. FIG. 1 is a vertical sectional view of a mold motor of the present invention. As shown in FIG. 1, this mold motor has a stator A, a rotor B, and a rotation axis C, and has teeth 1b, 2b of the stator core 1 with an insulator (insulator) 2 interposed therebetween.
The coil 3 (stator winding) is wound in a toroidal shape on the yokes 1c and 2c extending in between, and a premix made of an electrically insulating synthetic resin such as unsaturated polyester resin is filled and molded from the outside. The frame 4 is formed by.

Here, as shown in FIG. 4, the stator core 1 has a semi-donut-like (arc-shaped) semi-doughnut-like (arc-shaped) electromagnetic steel plate which is laminated by stacking a plurality of electromagnetic steel plates, and the projections 5 are joined together by crimping. The (arc-shaped) iron cores 1a, 2a are respectively provided with an insulator (semi-doughnut-shaped (arc-shaped) as will be described later) and a coil 3, which are abutted against each other in that state, and then mold-bonded with the synthetic resin. It is obtained by forming a donut shape (annular shape).

Further, in FIG. 1, the frame 4 is provided with a bearing housing 6 integrally formed with the frame 4 on one side in the axial direction. A bracket 9 formed by drawing a steel plate is provided on the other side of the frame 4 in the axial direction.
The rotor B is supported by a bearing 11 and a bearing 7 which are fixed to the inside and are fitted inside.

The rotor B has a printed circuit board 12 which will be described later.
A ring-shaped plastic magnet 8 is mounted at a position facing the Hall element (or Hall IC) H of FIG.
Further, as will be described later, the insulator 2 of the stator A composed of the stator core 1, the insulator (insulating member) 2 and the coil 3 has a substantially donut shape in which drive circuit components such as the Hall element H are mounted. The (annular) printed circuit board 12 is mounted, and the mounting position of the printed circuit board 12 is on the coil end side of the stator A and does not contact the coil 3.
The stator core 1 with the coil 3 mounted thereon is integrally molded and solidified with a synthetic resin having electric insulation to form the stator A. At this time, the printed circuit board 12 is also embedded in the resin.

The printed circuit board 12 has a plurality of connecting portions 2 to which terminals 13 to which a power source is connected and coils 3 are connected.
4 (described later) and a plurality of wiring patterns are formed. For example, in the case of four poles, as shown in FIG. 2 (FIG. 18), wiring patterns of D, E, F, G, N are formed, and 2
In the case of poles, as shown in FIG. 3 (FIG. 9), I, J, K, L,
An M wiring pattern is formed.

The printed circuit board 12 has a plurality of connecting portions 24, ...
The connecting portion 24 is formed so as to widen toward the front side, and the wiring patterns D, E, F, G, N, and
The wiring pattern 25 extending from I, J, K, L, and M to the surface of the connecting portion 24 is in a divergent shape similar to the connecting portion 24. Then, the lead wire 26 of the coil 3 is wound around the connection portion 24 including the wiring pattern 25 and soldered.

On the other hand, on the printed circuit board 12, as shown in FIGS. 2 and 3, the plural kinds of wiring patterns (4 poles, 2 poles, 2 poles) are used.
Holding pin 2 of the printed circuit board 12 at a position avoiding
A contact portion 28 for 7 is provided. That is, in the case of 4 poles, a wiring pattern of D, E, F, G, N is formed as shown in FIG. 2, and in the case of 2 poles, as shown in FIG.
The J, K, L, and M wiring patterns are formed, but the contact portion 2 for the holding pin 27 provided on the printed circuit board 12 is formed.
8 are arranged at similar positions as shown in FIGS. 2 and 3, and in all cases, all wiring patterns D, E, F, G, N,
The position avoids I, J, K, L, and M.

On the printed circuit board 12, the terminals 13 are provided.
A lead wire 15 for supplying electric power is attached to the lead wire 15. The lead wire 15 is fixed to the lead wire by a bush 16 made of a synthetic resin such as polybutylene terephthalate or the like. It is designed to be protected from pressure and to improve adhesion with resin.

The bush 16 comprises a pair of bush pieces 18, 19 which are superposed on each other via a thin connecting piece 17, as shown in FIGS.
A plurality of grooves 18b, 19 having different depths corresponding to the plurality of lead wires 15 are formed on each of the overlapping surfaces 18a, 19a.
b is formed. That is, the groove 18b of the bush piece 18 on the upper side of the bush 16 has a semicircular cross section (18
On the other hand, the groove 19b of the bush piece 19 on the lower side of the bush 16 is formed to have a cross section larger than a semi-round shape (180 degrees). As a result, the groove 18b is shallow and the groove 19b is deep.

Further, four through holes 20 are formed on the overlapping surface 19a of the bush piece 19, and the overlapping surface 18a of the other bush piece 18 is formed to be shorter than the depth X of the through hole 20. Four protrusions 2 of height Y to fit 20
1 is formed. While the bush 16 holds the lead wire 15 by the plurality of grooves 18b and 19b, at the same time as the resin molding of the stator core 1 around which the coil 3 is wound, about half of the bush 16 main body is integrally embedded in the resin and fixed. Fixed to child A.

The plastic magnet 8 is formed of a plastic magnet in which ferrite and a thermoplastic synthetic resin are mixed, and this thermoplastic synthetic resin has a coefficient of thermal expansion similar to that of an aluminum end ring 22 described later. are doing.

On the other hand, the rotor B is formed by casting an iron core by aluminum die casting, and the ring magnet is attached to the step portion 23 of the end ring 22 with an adhesive.

As shown in FIG. 13, such a molded motor has an insulator 2 attached thereto, is coupled in a donut shape (annular shape), and has a stator core 1 on which a coil 3 and a printed circuit board 12 are attached. It is set in a mold composed of a mold 29 and a lower mold 30, and a synthetic resin composed of unsaturated polyester is injected from two injection ports 31 to mold the stator A.

Here, at the time of injecting the synthetic resin, the holding pin 27 projects from the upper mold 29 (thereby, the hole 28A is formed on the back surface of the frame 4 as shown in FIG. 11), and the contact portion of the printed circuit board 12 is formed. The printed circuit board 12 is positioned and held by hitting 28. In this case, the holding pin 27 and the contact portion 28 have the wiring patterns D, E, F, G, N for the four poles and the wiring patterns I, J, for the two poles as described above.
The position avoids both K, L, and M.

The holding pin 27 prevents the printed board 12 from being displaced or deformed by heat or pressure when the synthetic resin is injected, and the printed board 12 is solidified together with the stator A at a predetermined position.

Further, two injection ports 31 are provided at positions opposite to the lower die 30 so as to be at right angles to the abutting surfaces of the semi-doughnut-shaped (arc-shaped) iron cores 1a, 2a constituting the stator iron core 1. Has been formed.

Here, the insulator 2 is mounted on the stator core 1 and the coil 3 is wound on the stator core 1. The insulator 2 is a semi-doughnut shape (as shown in FIGS. 14 to 17). A pair of insulating pieces 34, 35 and 36, 37 in an arc shape, each of which has a semi-doughnut-shaped (arc shape) iron core 1a,
Attach to 2a from above and below. At this time, the insulating pieces 34, 35
And the skirt portions 34a of 36 and 37, (insulating piece 35 is not shown) and 36a (insulating piece 37 are not shown) overlap, whereby the iron core 1
It is configured to be able to cope with variations in the thickness of a and 2a.

In this state, the coil 3 is wound, and the insulator 2 is also formed into a donut shape (annular shape) by butt-joining each other, and the butted portion W on one side surface thereof is formed.
A large-diameter pin 38 is provided on the top surface of the radial rib on the side, and a small-diameter pin 39 is provided on the top surface of the radial rib on the side opposite to the abutting portion Z on one side. .
The large-diameter pin 38 is located on the tip side of the teeth 1b, 2b, and the small-diameter pin 39 is located on the yoke 1c, 2c side. Then, the large and small pins 38 and 39 are inserted and fitted into the large hole 40 and the small hole 41 which are pre-drilled in the printed circuit board 12 as shown in FIGS. As a result, the printed circuit board 12 is held by the insulator 2, and the two iron cores 1a and 2a of the stator core 1 are also joined by the printed circuit board 12 in an annular shape.

In the molded motor thus constructed, the pins 38 and 39 of the insulator 2 are connected to the printed board 12
Since the semi-doughnut-shaped iron cores 1a and 2a can be positioned and joined by fitting in the large-diameter hole 40 and the small-diameter hole 41 of FIG. It can be abolished to reduce the man-hours required for manufacturing and improve the electromagnetic characteristics of the stator core.

In addition, a semi-doughnut-shaped (arc-shaped) insulating piece 3
Large-diameter pin 3 on the butting portion W side on one side of 4, 36
8 is projected, and a small diameter pin 39 is projected on the side opposite to the abutting portion Z, so that the vicinity of the abutting portion, which is greatly affected by the strength of the coupling, is made a large diameter pin 38 and the two iron cores 1a, 2a You can increase your strength. And
The large diameter pin 38 is located on the tip side of the teeth 1b, 2b, and the small diameter pin 39 is the yoke 1c, 2c around which the coil 3 is wound.
Since it is located on the side, the pin 39 does not interfere with the winding work of the coil 3. Therefore, the winding work can be performed smoothly while maintaining the holding force of the printed circuit board 12.

Further, as shown in FIG. 13, the synthetic resin for integrally molding the stator A is injected from a direction substantially orthogonal to the abutting surfaces of the two iron cores 1a, 2a constituting the stator core 1. Therefore, when injecting the synthetic resin, the two iron cores 1a and 2a can be pressed in the butting direction by the resin, and at the time of solidification, the two iron cores 1a and 2a can be firmly bonded.

Further, the wiring pattern 2 provided on the surface of the plurality of connecting portions 24 formed on the edge of the printed circuit board 12.
Since the shape of 5 is a divergent shape similar to the shape of the connecting portion 24, when the lead wire 26 of the coil 3 is wound around the connecting portion 24, the lead wire 26 is formed at least at both edges of the connecting portion 24.
And the wiring pattern 25 can be surely brought into close contact with each other,
Even if the lead wire 26 floats up in the center of the connection portion 24, the lead wire 26 and the wiring pattern 25 can be reliably connected to each other to prevent contact failure, and a highly reliable molded motor can be obtained.

The contact portion 28 of the holding pin 27 formed on the printed circuit board 12 has wiring patterns D, E,
F, G, N and wiring patterns I, J, K, L, for two poles
Since the printed wiring board 12 is positioned so as to avoid both M and M, the holding pin 27 is prevented from hitting both wiring patterns regardless of whether the printed circuit board 12 has a four-pole wiring pattern or a two-pole wiring pattern. Accept printed circuit board 12
Thus, when the stator A is molded with the synthetic resin, the printed circuit board 12 can be stably held, and the deformation and position shift of the printed circuit board 12 due to heat and pressure during solidification can be effectively prevented. As a result, the printed circuit board 12 and the molds 29 and 30 can be shared, and the manufacturing cost can be reduced.

The material of the ring-shaped magnet 8 attached to the end ring 22 of the rotor B for position detection is a plastic magnet, and this plastic has a coefficient of thermal expansion of aluminum (or zinc) used for die casting. Since they are close to each other, even if the rotor B is heated by the heat during the operation, the expansion and contraction are similar to those of the end ring 22, and the heat distortion is not generated in the magnet.
It is possible to prevent the breakage of the magnet, facilitate the molding management of the rotor B, and provide a molded motor having excellent durability and reliability.

Further, since the groove 19b of the bush piece 19 on the lower side of the bush 16 is formed to have a sectional shape larger than a semicircular shape (180 degrees), the lead wire 15 should be firmly held by this groove 19b. Therefore, even if heat or pressure is applied during molding of the stator core 1, the lead wire 15 can be reliably positioned in the groove 19b. As a result, the assembling workability can be improved by the simple structure in which the depth of the groove 19b of the one bush piece 19 is increased.

That is, since the groove 19b having a large depth has an arc shape whose cross-sectional shape is larger than a true semicircle, the lead wire 15 is surely held by the edges protruding at both ends of this arc. It is possible. However, the groove 19b does not necessarily have to be formed larger than the true semicircle, and the same effect can be obtained by merely forming the groove deeper than the true semicircle.

Further, four through holes 20 are formed on the overlapping surface 19a of the bush piece 19, and the overlapping surface 18a of the other bush piece 18 is formed to be shorter than the depth X of the through hole 20. Four protrusions 2 of height Y to fit 20
Since 1 is formed, a part of the through hole 20 remains hollow when the bush pieces 18 and 19 are fitted together. Since resin infiltrates into this cavity when the stator core 1 is molded and solidifies, the binding force between the bush pieces 18 and 19 and the fixing of the bush 16 itself become stronger, and the bush 16 is firmly fixed to the stator core 1. To be done.

Therefore, the lead wire 15 is hardly disengaged from the bush 16 even when the molded motor is used, and the bush 16 does not fall off the stator A even if it is aged. It is possible to obtain a molded motor having excellent properties and reliability.

In the above embodiment, the stator core 1 is composed of half-doughnut-shaped (180 ° arc-shaped) cores 1a and 2a, and the insulator 2 is also composed of half-doughnut-shaped insulating pieces 34, 35 and 36, 37. However, the present invention is not limited to this, and a large number of arc-shaped iron cores or insulating pieces having smaller angles may be butted against each other to form an annular stator iron core and insulator.

Further, although the embodiment is premised on a DC motor, it goes without saying that the same operational effect can be obtained even when applied to an induction motor.

[0051]

As described above, according to the invention of claim 1,
By fitting the pins of the insulating member to the predetermined positions on the printed circuit board, it is possible to position multiple arc-shaped iron cores and form an annular stator iron core. It is possible to reduce the number of working hours and improve the electromagnetic characteristics of the stator core.

Further, according to the invention of claim 2, in addition to the above, the diameter of the pin on the abutting portion side of each iron core is made larger than the diameter of the other pins, so that the strength of the connection is greatly affected. It is possible to increase the binding force of each iron core near the butted portion.

Further, according to the invention of claim 3, in addition to claim 1, the pin located on the tip side of the tooth portion of the stator core has a large diameter and the pin located on the yoke side has a small diameter. Therefore, the coil winding operation can be smoothly performed while maintaining the holding force of the printed circuit board.

[Brief description of drawings]

FIG. 1 is a vertical cross-sectional view of a mold motor showing an embodiment of the present invention.

FIG. 2 is a plan sectional view of a 4-pole mold motor.

FIG. 3 is a plan sectional view of a two-pole molded motor.

FIG. 4 is a plan view of a stator core.

FIG. 5 is a developed plan view of a bush.

FIG. 6 is a developed sectional view of a bush.

FIG. 7 is an exploded front view of the bush.

FIG. 8 is a front view of the rotor.

FIG. 9 is a plan view of a stator before being molded.

FIG. 10 is a vertical sectional view of a stator.

FIG. 11 is a rear view of the stator.

FIG. 12 is a front view of a stator.

FIG. 13 is a vertical cross-sectional view of a mold showing a manufacturing process of a mold motor.

FIG. 14 is a side view of an insulator mounted on a stator core.

FIG. 15 is a plan view of an insulator mounted on a stator core.

FIG. 16 is a side view of an insulating piece.

FIG. 17 is a front view of an insulating piece.

FIG. 18 is a plan view of a printed circuit board of a 4-pole mold motor.

FIG. 19 is a vertical sectional view showing a conventional mold motor.

[Explanation of symbols]

 A Stator B Rotor C Rotating shaft 1 Stator core 2 Insulator (insulating member) 3 Coil (stator winding) 4 Frame 12 Printed circuit board 34, 35, 36, 37 Insulating piece 38 Large diameter pin 39 Small diameter Pin 40 Large diameter hole 41 Small diameter hole

Claims (3)

[Claims] 1. A mold motor comprising a stator wound with a stator winding and an annular printed circuit board disposed on the coil end side integrally molded with a synthetic resin having electrical insulation properties. Cover each of a plurality of arc-shaped iron cores formed by butting with an insulating member formed of a synthetic resin, and then, a stator winding is wound around each of the iron cores and each of the insulating cores is insulated. A mold formed into an annular shape by fitting a pin projecting from the member toward the coil end side and integrally formed with the insulating member to a predetermined position of an annular printed circuit board to position the iron core. motor. 2. The molded motor according to claim 1, wherein the diameter of the pin on the abutting portion side of each iron core is made larger than the diameter of the other pins. 3. The stator is composed of a plurality of teeth and a yoke, the pin located on the tip side of the teeth has a large diameter, and the pin located on the yoke side has a small diameter. Item 1. The molded motor according to item 1.