JPH11225453A - Manufacture of stator core and stator for resin-molded motor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a stator core, for a resin-molded motor, in which cracks on a printed-wiring board and troubles in a soldering operation can be reduced. SOLUTION: A resin-molded motor is provided with a stator core 1, constituted in such a way that a plurality of ring-shaped cores 3, 4 having grooves in the outer circumference are laminated, with a winding 5 which is wound on the stator core 1 and with a printed-wiring board 7 arranged and installed in the lamination direction of the stator core 1, in order to electrically connect the winding 5 to a lead wire 6. Then, on their outer circumference, paired reference faces 18 which come into contact with reference faces 15 as references in the mold fitting operation of a resin molding mold 13 to the stator core 1 prior to a molding operation at a stator 2 for the resin-molded motor molded of an insulating resin 9 by leaving the soldering face 8 of the lead wire 6 on the printed-wiring board 7 constituted of the iron cores 4 on a side close to the printed-wiring board 7.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a printed wiring board for electrically connecting a winding wound around a stator core to a lead wire, wherein the stator core and the winding are formed of an insulating resin. The present invention relates to a method for manufacturing a stator core of a resin-molded electric motor and a stator.

[0002]

2. Description of the Related Art The above-mentioned resin-molded electric motor of this type has a structure as shown in, for example, Japanese Utility Model Laid-Open No. 6-77458. That is, as shown in FIG. 4, the stator 2A includes a stator core 1A formed by laminating a plurality of ring-shaped iron cores 3 of the same shape and size, and the stator core 1A.
A, and a printed wiring board 7 disposed in the stacking direction of the stator core 1 </ b> A for electrically connecting the winding 5 to the lead wire 6, The outer periphery is molded with an insulating resin 9 except for a soldering surface 8 of the printed wiring board 7 on the side to be soldered. On the center line of the stator 2A, a rotating shaft 27 is rotatably supported at both ends by bearings 28. A rotating yoke 29 is fitted to the rotating shaft 27, and a rotor core 30 integrated with the rotating yoke 29 is provided. The stator core 1A is opposed to the stator core 1A with an air gap.

[0005] Conventionally, the molding using the insulating resin 9 for the stator 2A of the resin-molded electric motor having such a configuration is performed by using a fixed mold 11 and a movable mold 1 as shown in FIG.
2 has been carried out using a separate resin mold 13. On the movable mold 12 of the resin mold 13, a stator (hereinafter also referred to as a work) as an assembly before molding is provided.
14A is set on one of the bearing holding portions 1.
6 is provided on the end face of the protruding portion 17 for molding the same. The fixed-side mold 11 is provided with a protrusion 19 for forming the other bearing holding portion 16 and a holding surface 20 which is on one side of the printed wiring board 7. A molding space 22 that forms the outer periphery of the mold portion of the stator 2A is formed in the resin mold 13 that has been molded on the mating surface 21.

[0004] The stator 14A before molding is such that the both ends of the stator core 1A are covered with a core insulating material 23, the winding 5 is wound thereon, and a pin implanted at one end of the core insulating material 23 is provided. 2
The printed wiring board 7 is mounted on the end face of the core insulating material 23 and soldered with the terminal of the winding 5 wound around 4. This work 14A is inserted into the molding space 2 of the movable mold 12.
2 is inserted until the reference surface 15 of the stator core 1A, which is the end surface of the stator core 1A on the side opposite to the printed wiring board, abuts on the reference surface 15 of the movable mold 12, and the movable mold 12 is fixed together with the work 14A. Moved to the mold 11 side, the fixed mold 11
With the movable mold 12 and the movable mold 12 being fitted on the mating surface 21,
An insulating resin is injected into the molding space 22 from the injection port 25, and the work 14A is subjected to a molding process. If the fixed mold 11 and the movable mold 12 are opened and taken out after a cooling period, the stator 2A molded with the insulating resin 9 is obtained.

[0005]

In the above-described stator 2A of the conventional resin-molded electric motor, the insulating resin 9 extends to the soldering surface 8 of the printed wiring board 7,
There is a problem that it often adheres there and hinders soldering. The cause is that the dimension from the reference surface 15 of the resin mold 13 to the holding surface 20 which hits the printed wiring board 7 is larger than the dimension from the reference surface 18 of the work 14A to the soldering surface 8 of the printed wiring board 7. That is. That is, as shown in FIG. 5, the distance P at which the soldering surface 8 of the printed wiring board 7 is held in the resin mold 13 is equal to the thickness L of the stator core 1A from the reference surface 15 and the core insulating material. The total distance of the height A of 23 and the thickness B of the printed wiring board 7 (P = L + A + B)
It is.

[0006] Thickness variation of each core 3 is large,
The greater the number of stacked layers, the greater the variation in the value of the stack thickness L,
Since the size of the resin mold 13 is determined in consideration of the maximum amount of the change, most of the size of the resin mold 13 is larger than the size of the work 14A. The reason for determining the dimensions of the resin mold 13 in consideration of the maximum change is that if the distance P of the resin mold 13 becomes shorter than the distance P of the work 14A, the printed wiring board 7 will Is applied, and the printed wiring board 7 is broken.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned conventional problems, and an object thereof is to solve the problem that the distance from the reference surface of the resin mold to the printed wiring board is increased even when the number of laminations increases. The development of stator cores for resin-molded motors that can reduce variations in the printed wiring board and reduce the risk of cracking and soldering of the printed wiring board. It is an object of the present invention to develop a method for manufacturing a stator of a resin-molded electric motor, which can reduce the occurrence of the problem.

[0008]

In order to achieve the above object, an invention according to claim 1 includes a stator core formed by laminating a plurality of ring-shaped cores each having a groove on an outer periphery; It has a wound winding and a printed wiring board arranged in a stacking direction of a stator core for electrically connecting the winding to a lead wire. Leave the surface on the side where the lead wires of the board are to be soldered, and mold it with insulating resin. Means is adopted in which the reference surface to be brought into contact with the core near the printed wiring board is adopted.

In order to achieve the above object, a second aspect of the present invention is to increase the inner diameter of the means according to the first aspect except for some of the iron cores on the side closer to the printed wiring board, and the inner diameter is increased. Means for forming a reference surface with the changing step portion is employed.

In order to achieve the above object, a third aspect of the present invention is to provide a method according to the first aspect, wherein the outer diameter of the iron core is reduced except for a few of the iron cores on the side close to the printed circuit board. Means for forming a reference surface with a step portion whose diameter changes is adopted.

In order to achieve the above object, a fourth aspect of the present invention provides a stator core formed by laminating a plurality of ring-shaped cores having a groove on the outer periphery, and a winding wound on the stator core. And a printed wiring board arranged in the stacking direction of the stator core for electrically connecting the windings to the lead wires. In manufacturing the stator of a resin-molded electric motor molded with insulating resin while leaving the surface to be attached,
The stator core before being molded with insulating resin, the reference surface that abuts the reference surface that is the reference when the resin mold is inserted is configured with the iron core closer to the printed circuit board,
A means for injecting the insulating resin into the molding space and performing molding is adopted such that the reference surface and the surface to be soldered of the printed wiring board are brought into contact with the surface on the molding space side of the resin mold.

In order to achieve the above object, a fifth aspect of the present invention provides the above-described means, wherein the inner diameter of the iron core except for a few of the iron cores on the side close to the printed circuit board is increased. Means for forming a reference surface with the changing step portion is employed.

In order to achieve the above object, the invention according to claim 6 is characterized in that, in the means according to claim 4, the outer diameter of the iron core is reduced except for some of the iron cores near the printed circuit board. Means for forming a reference surface with a step portion whose diameter changes is adopted.

In order to achieve the above object, the invention according to claim 7 is characterized in that, in the means according to claim 4, the number of iron cores on the side closer to the printed circuit board is located at a position where the winding of the stator core is not wound. Except for the sheet, a through hole is provided, and means for forming a reference surface with the bottom of the hole is adopted.

[0015]

Embodiments of the present invention will now be described with reference to the drawings. Embodiment 1 FIG. Embodiment 1 shown in FIG. 1 relates to a method for manufacturing a stator core 1 and a stator 2 of a resin mold electric motor. The stator 2 is wound around a stator core 1 configured by laminating a plurality of ring-shaped cores 3 and 4 having a groove (not shown) on the outer periphery, and a groove of the stator core 1. Winding 5 and a lead wire 6
And a printed wiring board 7 arranged in the stacking direction of the stator core 1 for electrically connecting the printed circuit board 7 to the outside. Are molded with the insulating resin 9.

A rotary shaft (not shown) is rotatably supported by a bearing on the center line of the stator 2, a rotary yoke is fitted to the rotary shaft, and a rotor core integrated with the rotary yoke is a stator. The resin-molded electric motor is configured to be opposed to the iron core 1 while holding a gap. The lead wire 6 is electrically connected directly to the winding 5 or indirectly via a capacitor (not shown), and is soldered to the soldering surface 8 of the printed wiring board 7. The stator 2 has a feature in the stator core 1 except for a few cores 4 on the side closer to the printed circuit board 7 among the cores 3 and 4 constituting the stator core 1. An inner diameter is configured to be large, and a step portion 10 whose inner diameter changes is configured.

Molding of the stator 2 of the resin-molded electric motor having the above-described structure with the insulating resin 9 is performed using a resin mold 13 separated into a fixed mold 11 and a movable mold 12 as shown in FIG. Thus, the stator 2 is manufactured. On the movable mold 12 of the resin mold 13, a stator (hereinafter also referred to as a work) as an assembly before molding is provided.
14 is set on one of the bearing holding portions 16
Is provided on the end face of the protruding portion 17 for molding. As shown in FIG. 1, the reference surface 15 contacts the reference surface 18 formed by the step 10 of the stator core 1 when the work 14 is formed. The fixed side mold 11 has a projection 19 for molding the other bearing holding portion 16 and a soldering surface 8 of the printed wiring board 7.
And a holding surface 20 is provided. The stator 2 is placed in the resin mold 13 that has been mated on the mating surface 21.
A molding space 22 (filled with the insulating resin 9 in the figure) which forms the outer periphery of the mold portion is formed.

The stator 14 before molding is a stator core 1
Are covered with an iron core insulating material 23 formed of an insulating resin, and the winding 5 is wound thereon, and the terminal of the winding 5 is connected to a pin 24 planted at one end of the core insulating material 23. In this embodiment, the printed wiring board 7 is mounted on the end surface of the core insulating material 23 and soldered. This work 14 is placed in the molding space 22 of the movable mold 12,
Reference surface 18 formed by stepped portion 10 of stator core 1
The movable mold 12 is moved together with the work 14 to the fixed mold 11 side, and the fixed mold 11 and the movable mold 12 are joined together by the mating surface 21. An insulating resin is injected into the molding space 22 from the inlet 25 and the work 14 is subjected to a molding process. If the fixed mold 11 and the movable mold 12 are opened and taken out after a certain cooling period, the stator 2 molded with the insulating resin 9 can be manufactured.

The distance Q at which the soldering surface 8 of the printed wiring board 7 of the work 14 in the clamped state is held in the resin mold 13 is the distance Q from the reference surface 15 of the iron core 4 having a small inner diameter of the stator core 1. The thickness M, the height A of the core insulating material 23,
Total distance of thickness B of printed wiring board 7 (Q = M + A
+ B). The variation in the thickness of each of the cores 3 and 4 is large, and the greater the number of laminated cores, the greater the variation in the overall thickness. However, the reference surface 18 is formed by the end surface of the core 4 having a small inner diameter. Therefore, the thickness M of the iron core 4 having a small inner diameter
Is much smaller than in the prior art, and the distance Q is shorter. Therefore, when the work 14 is set with the reference surface 18 against the reference surface 15 of the resin mold 13, the variation in the distance Q from the reference surface 15 to the soldering surface 8 of the printed wiring board 7 includes the inner diameter. Does not include the variation in the thickness of the iron core 3 having a large value. In other words, only the variation in the stack thickness of the several cores 4 having a small inner diameter affects the position of the printed wiring board 7 during the molding process, so that the insulating resin 9 reaches the soldering surface 8 of the printed wiring board 7. Also, the printed wiring board 7 is less likely to be attached to the printed wiring board 7, and the printed wiring board 7 is less likely to be broken when a stress is applied to the printed wiring board 7 when the molds are matched. Therefore, the productivity and quality of the stator 2 of the resin mold electric motor can be improved.

Here, the number of the iron cores 4 having a small inner diameter is selected as small as possible as long as it can withstand the stress applied to the iron cores 4 during molding, or the movable side mold 12 and the fixed side mold 11 are selected. Are combined, the soldering surface 8 of the printed wiring board 7 and the holding surface 2 of the fixed mold 11 can be formed due to the variation of the distance P shown in the section of the prior art.
The gap formed between 0 and 0 may be determined as the number of sheets that can be absorbed by elastically deforming the iron core 4 having a small inner diameter.

Embodiment 2 FIG. The second embodiment shown in FIG. 2 also relates to a method of manufacturing a stator core and a stator of a resin-molded electric motor, as in the first embodiment, and has the same basic configuration as the first embodiment. Therefore, the same parts as those in the first embodiment are denoted by the same reference numerals as those in the first embodiment, and the description thereof will be omitted.

The stator 2 of the second embodiment shown in FIG. 2 has a small outer diameter except for some of the cores 3 and 4 of the stator core 1 which are closer to the printed wiring board 7. Make up,
The reference surface 18 is formed on the outer peripheral portion of the stator core 1 by the step portion 10 whose outer diameter changes. Movable mold 12
Also, a reference plane 15 is provided at a position corresponding to this. By forming the reference surface 18 on the outer peripheral portion in this manner,
The area of the reference surface 18 can be made large, and a stable reference can be obtained. Other configurations and manufacturing methods are the same as those of the first embodiment, and the same operation and effects as those of the first embodiment can be obtained. If there is a limit on the outer diameter, the shape of the step portion 10 may be changed within the range of the limit.

Embodiment 3 FIG. The third embodiment shown in FIG. 3 also relates to a method of manufacturing a stator core and a stator of a resin-molded electric motor similarly to the first embodiment, and the basic configuration is the same as that of the first embodiment. Therefore, the same parts as those in the first embodiment are denoted by the same reference numerals as those in the first embodiment, and the description thereof will be omitted.

The stator 2 according to the third embodiment shown in FIG. 3 is provided at an arbitrary position where the winding 5 of the stator core 1 is not wound, of the iron cores 3 and 4 on the side closer to the printed wiring board 7. A hole 26 penetrating the other iron cores 3 is provided except for several of the cores 4, and the reference surface 18 is formed by the bottom of the hole 26. This hole 2 is also provided in the movable mold 12 at the corresponding position.
A reference surface 15 is provided, which enters into 6 and abuts against the reference surface 18. By forming the reference surface 18 within the radial thickness of the stator core 1 in this manner, a stable reference can be made without being restricted by the inner and outer diameters of the stator core 1.
Other configurations and manufacturing methods are the same as those of the first embodiment, and the same operation and effects as those of the first embodiment can be obtained.

[0025]

As is apparent from the above description of the embodiments, according to the first, second and third aspects of the present invention, even if the number of laminations is large, the standard of the resin mold is larger. A stator core of a resin-molded electric motor can be obtained in which variation in the distance from the surface to the printed wiring board can be reduced, and breakage of the printed wiring board and hindrance to soldering can be reduced.

Claim 4, Claim 5, Claim 6, Claim 7
According to each of the inventions described above, it is possible to obtain a method of manufacturing a stator of a resin-molded electric motor with high productivity, which can reduce the possibility of breaking the printed wiring board and hindering soldering.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing a stator during a molding process according to a first embodiment together with a resin mold.

FIG. 2 is a cross-sectional view showing a stator during a molding process and a resin mold according to a second embodiment.

FIG. 3 is a cross-sectional view showing a stator during a molding process and a resin mold according to a third embodiment.

FIG. 4 is a sectional view showing a conventional resin mold electric motor.

FIG. 5 is a cross-sectional view showing a stator during a molding process of a conventional resin mold electric motor together with a resin mold.

[Explanation of symbols]

1 stator core, 2 stator, 3 iron core, 4 iron core, 5 winding, 6 lead wire, 7 printed wiring board, 8 soldering surface, 9 insulating resin, 10 stepped portion, 13 resin mold, 15 reference surface , 1
8 reference plane, 20 holding surface, 22 molding space,
26 holes.

Continued on the front page. (72) Inventor Kouki Kieda 2-3-2 Marunouchi, Chiyoda-ku, Tokyo, Japan Mitsui Electric Co., Ltd. (72) Inventor Kazue Izawa 2-3-2, Marunouchi, Chiyoda-ku, Tokyo, Mitsubishi Inside Electric Co., Ltd. (72) Inventor Hideaki Miyagawa 2-3-2 Marunouchi, Chiyoda-ku, Tokyo Mitsubishi Electric Co., Ltd.

Claims (7)

[Claims] 1. A stator core formed by laminating a plurality of ring-shaped cores each having a groove on an outer periphery, a winding wound around the stator core, and the winding wound on a lead wire. Having a printed circuit board arranged in the stacking direction of the stator core for electrical connection,
The stator core before molding in the stator of the resin-molded electric motor, which is molded with an insulating resin except for the surface on the side where the lead wires of the printed wiring board are to be soldered, and a reference at the time of inserting a resin mold. A stator core for a resin-molded electric motor, wherein a reference surface that abuts on a reference surface is formed by an iron core closer to the printed wiring board. 2. The stator core of the resin-molded electric motor according to claim 1, wherein the inner diameter of the core except for a few of the iron cores on the side closer to the printed circuit board is large, and the step in which the inner diameter changes is provided. A stator core of a resin-molded electric motor, wherein a reference surface is formed by a portion. 3. The stator core of the resin-molded electric motor according to claim 1, wherein the outer diameter of the core is reduced except for some of the cores on the side close to the printed circuit board, and the outer diameter varies. A stator core of a resin-molded electric motor, wherein a reference surface is formed by a stepped portion. 4. A stator core formed by laminating a plurality of ring-shaped iron cores having grooves on the outer periphery, a winding wound on the stator core, and the winding wound on a lead wire. Having a printed circuit board arranged in the stacking direction of the stator core for electrical connection,
In manufacturing a stator of a resin-molded electric motor molded with insulating resin except for a surface of the printed wiring board on which the lead wires are to be soldered, a resin mold metal is provided on the stator core before molding with insulating resin. A reference surface which is in contact with a reference surface serving as a reference when the mold is inserted is constituted by an iron core on a side close to the printed circuit board, and the reference surface and the surface to be soldered of the printed circuit board are formed of the resin mold. A method for manufacturing a stator for a resin-molded electric motor, comprising: injecting the insulating resin into a molding space so as to be in contact with a surface of a mold on a molding space side; 5. The method of manufacturing a stator for a resin-molded electric motor according to claim 4, wherein the inner diameter of the iron core is increased except for some of the iron cores on the side closer to the printed wiring board, and the inner diameter varies. A method for manufacturing a stator for a resin-molded electric motor, comprising a stepped portion that forms a reference surface. 6. The method for manufacturing a stator for a resin-molded electric motor according to claim 4, wherein the outer diameter of the iron core is reduced except for a few of the iron cores on the side closer to the printed wiring board. A method for manufacturing a stator of a resin-molded electric motor, wherein a stepped portion having a change in the distance forms a reference surface. 7. The method for manufacturing a stator for a resin-molded electric motor according to claim 4, wherein the stator core includes a plurality of stator cores at positions where the windings of the stator cores are not wound. A method of manufacturing a stator for a resin-molded electric motor, characterized in that a through-hole is provided except for (1), and a reference surface is formed by a bottom of the hole.