JPS61269643A - Manufacture of stator for motor - Google Patents

Abstract

PURPOSE:To enhance productivity and prevent a rotor from generating torque ripple, by molding winding units out of insulating resin, and by cutting off the molded substance in ring shapes to form stator coils. CONSTITUTION:On the central sections of the wound cores 10, containing slots 10a are formed in the axial direction, and are externally opened by slits 10b in the axial direction. The slits 11a of copper pipes 11 contained in the containing slots 10a are made to correspond to the slits 10b. Through the slits 10b, the end sections of conductive plates 12 are pressed in the slits 11a, and the plates for the half length are wound up. After that, the other end sections of the conductive plates 12 are pressed in the slits 11a of the copper pipes 11 of other wound cores 10, and the plates for the residual half length are wound up. Two winding units 13 formed in this manner are molded 15 out of insulating resin 14. The molded substance 15 are cut off in ring shapes as shown in broken lines to produce stators.

Description

DETAILED DESCRIPTION OF THE INVENTION [Technical Field of the Invention] The present invention relates to a method for manufacturing a stator of a motor suitable for an axial gap type motor.

(Technical Background of the Invention) Conventionally, for example, the stator of an axial gap type brushless motor has a plurality of insulated conductive wires wound in a predetermined shape on an insulated substrate facing a rotor equipped with a permanent magnet. It was manufactured by arranging stator coils in a circular ring and fixing them individually with adhesive.

(Problems with the Background Art) In the conventional manufacturing method described above, each stator coil must be individually arranged and bonded on an insulating substrate, which takes time and reduces mass productivity. Since it is not possible to arrange and bond each stator coil at a predetermined position with high precision, there is a problem that this causes torque ripple in the rotor.

(Object of the Invention) The present invention has been made in view of the above circumstances, and its purpose is to provide a method for manufacturing a stator of a motor that is excellent in mass productivity and that can prevent torque ripples in the rotor as much as possible. There is something to do.

(Summary of the Invention) The present invention comprises winding a conductive plate into a cylindrical shape to form a winding body, molding the winding body arranged in a predetermined position with a highly resistant resin, and producing the molded product. is cut across the winding body to form a plurality of stator coils, thereby positioning the winding body in a highly accurate mold, and simultaneously energizing the stator coils. By forming the plurality of winding bodies constituting the product from a single IJ conductive plate, the connection between the stator coils can be simplified as much as possible!This is a unique feature.

[Embodiments of the invention]

An embodiment in which the present invention is applied to an axial gap type brushless motor will be described below with reference to the drawings. First, the structure of the stator Δ will be described based on FIGS. 1 and 2. 1 is a printed circuit board having a bearing sleeve 2 in the center, and 3 is a plurality of stator coils, for example, 4, manufactured as described below. These stator coils 3 are made of a disc-shaped molded body 4 made of insulating resin, for example, polyimide resin.
They are buried at predetermined angular intervals. Moreover, each of these stator coils 3 has two pieces (3a, 3b and 3C).
, 3d') are energized at the same time, that is, in phase, and are connected in series in the same winding direction. Further, an annular copper sunrise part 5 is formed at the inner winding end of each stator coil 3, and this sunrise part 5 is formed when the molded body 4 is stacked on the printed circuit board 1. It is connected to a conductive pattern (not shown) of the printed circuit board 1 by a grommet (not shown). On the other hand, the rotor yoke 7 has a flat circular container shape with an open bottom, and a permanent magnet 8 is disposed on the inner peripheral surface of the rotor yoke 7, and a shaft 9 is fitted in the center of the rotor yoke 7. There is. The shaft 9 is inserted into and supported by the bearing cylinder 2 of the printed circuit board 1, so that the stator coil 3 group and the permanent magnet 8 face each other with a predetermined gap therebetween.

Now, a method for manufacturing the stator A will be described based on FIGS. 3 to 5. Reference numeral 10 denotes a winding core having a substantially triangular prism shape, and a storage hole 10a extending in the axial direction is formed in the center of the core, and the storage hole 10a is opened to the outside through a slit 10b also extending in the axial direction. A copper pipe 11 is housed in the storage hole 10a of the winding core 10, and a slit 11a formed in the copper vibe 11 is aligned with a slit 10b of the winding core 10. On the other hand, 12 is a strip-shaped copper plate, which is a conductive plate, on one surface of which is formed an insulating layer (not shown) made of polyimide resin, for example. One end of this strip-shaped copper plate 12 is inserted into the slit 1 of the winding core 10.
0b into the slit 11a of the copper vibrator 11,
Approximately half the length is wound around the winding core 10 a predetermined number of times. Then, a copper via 16 is also stored in the storage hole 10a of another winding core 10, and the other end of the strip-shaped copper plate 12 is press-fitted into the slit 11a of the copper vibe 11 through the slit 10b of the winding core 10. The length is wound around the winding core 10 a predetermined number of times. As a result, a winding body 13 is constructed which has winding portions at two locations and has copper pipes 11 and 11 electrically connected to each other at both ends thereof (see Fig. 4). reference)
. Thereafter, only two of the winding bodies 13 thus formed are housed in a mold (not shown), and arranged at predetermined angular intervals by the positioning function of the mold. Then, an insulating resin (not shown), such as a polyimide resin, is supplied into the mold and solidified, and a molded product 15 is formed in which two winding bodies 13 and 13 are inserted into the polyimide resin layer 14.
(See Figure 5). In this case, each copper vibrator 11 is sealed, for example, by a mold to prevent the polyimide resin from flowing inside. Furthermore, each winding body 13 is formed using this molded product 15 as shown by the broken line in FIG.
The material is cut into so-called round slices to a predetermined thickness so as to cross the surface. Then, two stator coils 3 of the same phase connected in series are formed by cutting the 1vA winding body 13, so in the end, four stator coils 3a to 3d,
A molded body 4 is formed in which sunrise portions 5 formed by cutting a copper vibrator 11 are embedded in both ends of each of the stator coils 3a, 3b, 3c, and 3d of the same phase. Thereafter, the stator A is completed by stacking the printed circuit board 1 and the stator coil 3 and fixing them to each other with eyelets.

According to this embodiment, the following effects can be obtained. That is, a winding body 13 formed by winding a band-shaped copper plate 12 in a substantially triangular spiral shape is placed in a mold, molded with polyimide resin to form a molded product 15, and this molded product 15 is cut into rounds. Since the stator coil 3 is manufactured by cutting the stator coil 3 into pieces, it is superior in manufacturability and mass production compared to the conventional method of individually gluing a plurality of stator coils formed by winding insulated conductor wires. . Moreover, since the winding body 13 is reliably positioned at an accurate position by a highly accurate mold, each stator coil 3 is inevitably positioned at a set position with high accuracy, and therefore, the rotor 8 Torque ripple can be prevented as much as possible. Furthermore, the strip copper plate 12
By appropriately setting the thickness dimension of the insulating layer, the conductor spacing of the stator coil 3 can be set arbitrarily and with high precision, and the thickness of the strip-shaped copper plate 12 or the round thickness dimension of the molded product 15 can be set arbitrarily and with high precision. By appropriately setting , the motor characteristics can be set arbitrarily. Moreover, since the stator coils 3 that are energized at the same time are formed by a single band-shaped conductor 12, the two stator coils 3 of the same phase are connected in advance, and the stator coils 3 are connected in advance. Connection processing becomes extremely simple and manufacturability is further improved. In addition, especially in this embodiment, since the copper pipes 11.11 are provided at both ends of the strip conductor 12, the copper pipes 11.11 are provided at both ends of the two stator coils 3 of the same phase and connected in series in advance. An annular sunrise portion 5 is formed by cutting the material into rings. Therefore, if the molded body 4 is stacked on the printed circuit board 1 and the stopper is passed through the exposed portion 6 and the through hole of the printed circuit board 1 and caulked, the stator coil 3 is electrically connected to the conductive pattern of the printed circuit board 1. At the same time, it is firmly fixed to the printed circuit board 1.

This eliminates the need for soldering the stator coil 3 and the printed circuit board 1, and also eliminates the need for an adhesive application process unlike in the case of fixing by adhesion, which can further improve productivity. This makes it suitable for mass production.

In the above embodiment, the copper vibrator 11.1 is attached to the strip copper plate 12.
Although the cylindrical portion is formed by attaching the strip copper plate 12, the present invention is not limited to this. For example, the cylindrical portion may be formed integrally by curling both ends of the strip copper plate 12. The means is not limited to the grommet, and the sunrise portion 5 may be press-fitted into a conductive bottle protruding from the printed circuit board 1, for example.

[Effects of the Invention] As explained above, the present invention is characterized in that the windings are arranged in predetermined positions and molded with insulating resin, and the molded product is cut to form the stator coil. , it is excellent in mass production, can prevent torque ripples in the rotor as much as possible, and the winding body constituting the stator, which is energized at the same time, is formed from a single 1'4 plate. This has the excellent effect of simplifying the connection between the stator coils and further improving manufacturability.

[Brief explanation of drawings]

The drawings show one embodiment of the present invention, in which Fig. 1 is a cross-sectional view of the stator, Fig. 2 is a vertical sectional view of the entire brushless motor, Fig. 3 is a perspective view of the winding core and band-shaped conductor, and Fig. 4 is a cross-sectional view of the stator. A perspective view of the winding body. FIG. 5 is a perspective view of a molded product obtained by molding the winding body. In the figure, 3 is a stator coil, 12 is a strip copper plate (conductive plate)
, 13 is a winding body, 14 is a polyimide resin layer (insulating resin), and 15 is a molded product. Applicant: Toshiba Corporation Attorney: Tsuyoshi Sato Figure 1 Figure 2 Figure 4

Claims (1)

[Claims] 1. A conductive plate is wound into a cylindrical shape to form a winding body, the winding body is arranged in a predetermined position and molded with an insulating resin, and the molded product is passed across the winding body. The stator coil is cut to form a plurality of stator coils, and is characterized in that a plurality of winding bodies constituting those stator coils that are energized at the same time are formed from a single conductive plate. Motor stator manufacturing method.