JPS60241750A - Manufacture of stator of brushless motor - Google Patents

Abstract

PURPOSE:To manufacture in a mass production and to eliminate a torque ripple by annularly disposing a plurality of winding units in a mold to mold insulating resin, cutting the integral molding to form stators. CONSTITUTION:Winding units 17 of substantially triangular shape are formed of composite plates made of copper plates and polyimide resin plates, and 8 units 17 are disposed substantially annularly in a mold. Then, polyimide resin is supplied and solidified in the mold to obtain an integral molding 19. The molding 19 is laterally cut to manufacture stators.

Description

[Detailed Description of the Invention] [Technical Field of the Invention] The present invention relates to an axial gap type brushless motor Kj.
[Related to a method for manufacturing a stator of a brushless motor.]

[Technical background of the invention]

Conventionally, a stator used in an axial gap type brushless motor includes a surface portion K of a stator core facing a rotor made of a permanent magnet, and a winding formed by winding and forming an insulated conductive wire into a predetermined shape.

They are manufactured by arranging a plurality of them in an annular shape and fixing them individually with adhesive.

[Problems with background technology]

In the conventional manufacturing method described above, each winding must be individually arranged and glued on the surface of the stator core, which takes time and reduces mass productivity. Since it is not possible to achieve very high precision in alignment and bonding, there is a problem that this causes torque ripples to occur in the rotor.

[Purpose of the invention]

The present invention has been made in view of the above circumstances, and an object thereof is to provide a method for manufacturing a stator for a brushless motor that is excellent in mass productivity and can prevent tricripple in the rotor as much as possible.

[Summary of the invention]

The present invention involves arranging a plurality of winding bodies formed by winding conductive plates in a circular pattern, molding them with an insulating resin, and making this integral molding into a plurality of winding bodies. The stator is characterized in that it is cut transversely to form the stator, and the windings are positioned by the mold.

[Embodiments of the invention]

An embodiment of the present invention will be described below with reference to FIGS. 1 to 6.

First, the overall structure of the axial gap type brushless morph will be described with reference to FIGS. 1 and 2. 1 is a stator manufactured as described below, which is
It is constructed by disposing a plurality of windings 3 (eight in number) in a substantially annular shape on a substantially square support plate 2 made of an insulating resin, for example, a polyimide resin. Further, in the support plate 2, a circular mounting hole 4 is formed in the center part, and a mounting hole 5 is formed in the square part.
are formed respectively, and three adjacent windings 3.
A support hole 6.degree. 6 is formed at a portion located between the holes 5.5 and 5.5. A position detection element and a Hall element 7.7 are fitted and supported in the support hole 6.6 of the support plate 2. 8 is a rotor, which is constructed by disposing a permanent magnet 10 forming an inner peripheral part Kii1PM of a rotor core 9 which is shaped like a flat circular container with an open bottom surface.
A shaft 11 is provided to protrude downward from the center IIK.

The shaft 11 of this rotor 8 is connected to the front stator 1.
The permanent magnet 10 is inserted through and supported by a bearing 12 that is fitted and supported by the mounting q4, so that the winding 5 and the permanent magnet 10 face each other with a predetermined gap therebetween.

Now, a method for manufacturing the stator 1 will be described according to FIGS. 3 to 6. Reference numeral 15 denotes a long composite plate, which is constructed by attaching a polyimide resin plate 15, which is a highly dense plate, e.g., 10 μm thick, to the back side of a conductive plate, e.g., a steel plate 14, which has a thickness of 7 Dl1 m, by adhesion or the like. (See Figure 5). Then, one longitudinal end of this composite plate 13 is folded so that the cut steel plates 14 correspond to each other, thereby forming a terminal connection part 16 (see FIG. 4). Further, this composite plate 15 is wound in a substantially triangular spiral shape with the terminal connecting portion 16 facing inside, thereby forming a winding body 17 having a substantially pentagonal cylindrical shape (see FIG. 5). Eight of the winding bodies 17 thus formed are housed in a mold (not shown) and arranged in a substantially annular shape using the positioning function of the mold. Then, a molten metal of an insulating resin (not shown), such as a polyimide resin, is supplied into the mold and solidified, thereby molding an integrally molded product 19 in which eight winding bodies 17 are inserted into the polyimide resin layer 18. , shape (see Figure 6). In this case, the polyimide resin layer 18 has a rotor 0. A hole 21 corresponding to the attachment hole 5 and a hole 22 corresponding to the support hole 6 are formed by a mold during the molding. Furthermore, this integrally molded product 19 is made to cross the eight winding bodies 7 as shown by the broken line in FIG.
A stator structure can be formed by cutting the stator structure into a ring shape as required to have a thickness of ~1°OH, and it is preferable to stack a plurality of stator structures.The stator 1 shown in FIG. begins to form. In this case, it is also possible to increase the thickness of the cut and form the stator 1 with r pieces of stator components.

According to this embodiment, the following effects can be obtained. That is, the winding body 17 formed by winding the composite plate 13 in a substantially triangular spiral shape is arranged in a substantially annular shape in a mold by 811I and molded with polyimide resin to form an integrally molded product 19. Since the stator 1 is manufactured by cutting the integrally molded product 19 into slices, mass production is superior to the conventional case in which the windings are individually glued together. Since the position is reliably determined by the mold, the winding 5 of the stator 1 is also inevitably positioned at the set position, so that torque ripple in the rotor 81C can be prevented as much as possible.

Also, a support hole 6 for attaching the Hall element 7゜7 to the stator 1 is provided.
．． 6 is also formed by positioning with each winding body 17 using a mold, so the positioning of the Hall elements 7, 7 is ensured, and this also makes it possible to reduce the torque ripple of the rotor 8. . Furthermore, the conductor of winding IA5 (rope plate 14
) Since the intervals are uniform, the winding 5 can be made with high precision, and the thickness of the polyimide resin plate 15 can be adjusted to an appropriate i:1
By determining a, a winding wire with a desired conductor spacing can be manufactured. Moreover, desired motor characteristics can be obtained by appropriately selecting the thickness of the steel plate 14 of the composite plate 15 or the thickness of the ring of the integrally molded product 19.

FIG. 7 shows another embodiment of the present invention, which differs from the previous embodiment in that when the composite plate 13 is spirally wound, a core material 25 made of insulating resin having a substantially trapezoidal cross section is inserted. In this case, the Hall element 6 (see FIG. 2) is attached to the core material 25 through the hole 2.
5 is formed of stones.

It should be noted that the present invention is not limited to the embodiments described above and shown in the drawings, but can of course be implemented with appropriate modifications within the scope of the invention.

〔Effect of the invention〕

As explained above, the method of manufacturing a stator for a brushless motor according to the present invention involves arranging a plurality of wound bodies in a ring shape in a mold, molding them with insulating resin, and cutting the integral molding to form a stator. Since it is formed in such a manner that it is possible to form the rotor, it is excellent in mass productivity and has the excellent effect of being able to prevent torque ripples from occurring in the rotor as much as possible.

[Brief explanation of drawings]

Figures 1 to 6 show an embodiment of the present invention, with Figure 1 being a vertical sectional view of a brushless motor, Figure 2 being a top view of a stator, Figure 5 being a perspective view of a composite plate, and Figure 4 5 is a perspective view of a winding body, FIG. 6 is a perspective view of an integrally molded product, and FIG. 7 is a winding diagram showing another embodiment of the present invention. FIG. In the drawing, 1 is a stator, 2 is a support plate, 3 is a winding, 8 is a rotor, 9 is a rotor core, 10 is a permanent magnet, 15 is a composite plate, 14 is a wire plate (conductive plate), and 15 is a polyimide T! 16 is a terminal connection part, 17 is a winding body, 18 is a polyimide resin layer, 19 is an integrally molded product, and 24 is a winding body. Part 1 Part 2 Figure 3 Figure 4 Figure 1 Otsu 5 Figure 5

Claims (1)

[Claims] 1. A conductive plate is wound into a cylindrical shape, and a plurality of winding bodies are arranged in a ring shape, these are molded with insulating resin, and this integral molding is passed across the plurality of winding bodies. A method for manufacturing a stator for a brushless motor, characterized in that the stator is formed by cutting the stator in the following manner.