JPS61295844A - Stator - Google Patents

Abstract

PURPOSE:To improve the mass productivity and the working accuracy of a bearing by forming a hole which is axially extended in a molded product in which a plurality of cylindrical winding units are molded with resin, slicing it and then using the hole as a bearing. CONSTITUTION:A striplike conductive plate is wound in a cylindrical shape to form a winding unit 17, a plurality of units 17 are annularly disposed, molded with molding resin 5 to form a molded product 18. In this case, a hole 19 axially extended is formed at the center of the product 18. The product 18 is sliced in a plane perpendicular to the axial direction to form a stator coil molding unit. Then, the hole 19 is used as a bearing of a rotor. Thus, the bearing can be formed in an accurate mold to improve the mass productivity and to reduce a torque ripple of the rotor.

Description

DETAILED DESCRIPTION OF THE INVENTION [Technical Field of the Invention] The present invention relates to a stator in which a stator coil is molded with resin.

[Technical Preface of the Invention] Conventionally, the stator of, for example, an axial gap type brushless motor has been prepared by winding an insulated conductive wire into a predetermined shape on, for example, a metal substrate facing a rotor equipped with a permanent magnet. The structure was such that a plurality of winding bodies consisting of the above were arranged in an annular shape and each was fixed by adhesive, and a bearing supporting the rotating shaft of the rotor was fixed to the substrate.

[Problems with the Background Art] However, in the conventional configuration described above, the stator coils are formed by winding insulated conductors during manufacturing, these stator coils are individually bonded to a substrate, and then the bearings are further fixed to this substrate. The disadvantage was that it required labor-intensive work and was poor in mass production. Moreover, since multiple stator coils are arranged individually by adhesive, not only is it easy to lose the positional accuracy between each stator coil, but also when fixing the board to which the stator coils are glued to the bearing side, the stator filter The concentric precision with the bearing is likely to be distorted,
There is a drawback that these errors in precision cause torque ripple in the rotor.

[Object of the Invention] The present invention has been made in consideration of the above-mentioned circumstances, and therefore, its object is to provide a stator that is excellent in mass productivity and that can prevent torque ripples from occurring in the rotor as much as possible. .

[Summary of the Invention] The present invention provides a stator coil molded body by resin molding a plurality of winding bodies formed by winding conductive plates into a cylindrical shape, and cutting the molded product across the winding bodies. and forming a bearing part integrally with the stator coil mold body by cutting an axially extending hole formed integrally with the molded product by resin molding of the winding body together with the winding body. The rotating shaft of the rotor is supported by this ring bearing part, and the positioning of each winding body and hole is performed by the mold with high precision, and the stator coil mold body is cut by cutting the molded product. and a bearing part can be integrally formed.

[Embodiment of the Invention] Hereinafter, an embodiment in which the present invention is applied to an axial gap type brushless motor will be described with reference to FIGS. 1 to 5. Reference numeral 1 denotes a substrate made of gold a which also serves as a stator yoke, and a thrust bearing 2 is provided in a circular hole 1a formed in the center of the substrate. Reference numeral 3 denotes a stator coil molded body manufactured as described later and attached to the substrate 1, which includes, for example, four stator coils 4 arranged in an annular area as shown in FIG. It is molded with a mold resin 5 made of resin, and is formed into a disk shape having a circular hole-shaped bearing portion 6 in the center. The portions of the stator coil 4 corresponding to the winding start end on the inner circumferential side and the winding end portion on the outer circumferential side each form an annular shape! ! An outlet portion 7 made of No. 4 is provided. On the other hand, although not shown, a wiring pattern is formed on the substrate 1 via an insulating layer, and each of the opening portions 7 is connected to the wiring pattern by, for example, soldering. In contrast to the stator 8 constructed as described above, the rotor 9 has a permanent magnet 11 attached to the inner surface of the rotor yoke 10, which has a flat circular container shape with an open bottom surface, as shown in FIG. The rotary shaft 12 is located in the center of the rotary shaft 12. The rotating shaft 12 is rotatably inserted into and supported by the bearing portion 6 of the stator coil molded body 3, and the bearing portion 6 and the thrust bearing 2 allow the stator coil 4 group and the permanent magnet 11 to maintain a predetermined gap. They are now facing each other. Next, a method for manufacturing the stator coil mold body 3 will be described based on FIGS. 3 to 5. 13
The winding core has a substantially triangular prism shape, and a storage hole 13a extending in the axial direction is formed in the center of the core, and the storage hole 13a is opened to the outside through a slit 13b also extending in the axial direction.

A copper vibe 14 is stored in the storage hole 13a of the winding core 13,
The slit 14a formed in this copper pipe 14 is connected to the winding core 13.
It is made to coincide with the slit 13b of.

On the other hand, 15 has an insulating layer (for example, made of polyimide resin) on one side.
(not shown) is a strip-shaped copper plate that is a conductive plate. One end of this strip-shaped steel plate 15 is press-fitted into the slit 14a of the copper vibrator 14 through the slit 13b of the winding core 13.
Wrap multiple times around. Then, like the copper via 14, a copper via 16 having a slit 16a is press-fitted into the other end of the strip-shaped copper plate 15 with the slit 16a. As a result, a winding body 17 is constructed in which the copper vibrators 14 and 16 extending in the direction of the winding axis are electrically connected at the winding start end and the winding end (see FIG. 4). Thereafter, only four 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. The mold in this case has a ring-shaped molding protrusion (not shown) extending in the axial direction at the center, and the outer diameter of this molding protrusion is set to be the same as the outer diameter of the rotating shaft 12 of the rotor 9. are doing. Then, after sealing both ends of each copper vibrator 14, 16 with a mold to prevent the mold resin from entering inside, the mold resin is injected into the mold, and after the resin is assimilated, the mold is opened. The molded product 18 (see FIG. 5) is removed from the mold. This molded product 18
4 extending in the axial direction in the annular region inside the mold resin 5
A plurality of wire wire bodies 17 are buried therein, and a hole 19 extending in the axial direction is integrally formed in the center of each group of winding wire bodies 17 by the forming protrusion. After this, the molded product 18 is wrapped around the four winding bodies 17 and the hole 19 as shown by broken lines in FIG.
By cutting the winding body 17 across the annular region of the molded resin 5 in a so-called axial cut state, four stator coils 4 are formed in the annular region of the molded resin 5, and a hole is formed in the center of the molded resin 5. The stator coil molded body 3 is completed in which the bearing portion 5 is formed by cutting the coils 19 and the eye portions 7 are formed at the winding start and end portions of each winding body 17 by cutting the copper bis 114 and 16. . Thereafter, the stator coil molded body 3 is attached to the substrate 1, and each outlet portion 7 is soldered to a predetermined portion of the substrate 1, thereby completing the stator 8.

According to this embodiment, the following effects can be obtained. That is, the winding bodies 17 formed by winding the band-shaped steel plate 15 into a cylindrical shape are arranged in a substantially annular shape in a mold, and a hole 19 extending in the axial direction is formed in the center of the group of winding bodies 17. The molding is performed by positioning the molding protrusion of the molding die as much as possible, and the molded product 18 is cut into rings to integrally form the stator coil molded body 3 and the bearing portion 6, so that insulation is not required during manufacturing. Compared to the conventional method, which involved winding coated conductors to form stator coils, gluing these stator coils individually to a board, and then fixing the bearings to this board, which was a time-consuming process, mass production is easier. Becomes excellent. Moreover, since the winding body 17 and the hole 19 in the molded product 18 are reliably positioned at an accurate position by the positioning function of the mold, the stator coil 4 and the bearing part 6 are also necessarily positioned with high precision. Therefore, the occurrence of torque ripple in the rotor 9 can be prevented as much as possible.

In the above embodiment, the hole 19 is formed in the center of the molded product 18 by the forming protrusion of the mold, but the invention is not limited to this, and the hole 20 may be formed as shown in FIG. For example, the bearing member 21 made of sintered metal or sintered resin is resin-molded together with the winding body 17, and the molded product 18 is cut across the molded body to form the bearing part integrally with the stator coil molded body. You may also do this. In this case, since the bearing portion can be formed of an appropriate bearing material, the life of the bearing portion can be extended. Further, the motor incorporating the stator coil mold body 3 of the present invention is not limited to the axial gear type brushless motor as in the above embodiment, but, for example, as shown in FIG. A rotating shaft 24 is attached to the stator yoke 22.22 so as to face each other with a gap therebetween, and a permanent magnet 23 is positioned between both stators 8.8, and a rotating shaft 24 is fixed to the center of the permanent magnet 23 in a penetrating state. Both ends of the stator coil molded body 3゜3 bearing part 6,
The present invention can also be applied to a motor configured to be rotatably supported by the motor 6. In addition, the present invention can be modified in various ways without departing from the scope of the invention.

[Effects of the Invention] As is clear from the above description, the present invention provides a molded stator coil body and a bearing portion by cutting a hole integrally formed in a resin molded product of the winding body together with the winding body. Since the stator coils and bearings are integrally formed, the conventional stator coil gluing work and bearing fixing work are no longer necessary, making it excellent for mass production.Moreover, the positioning accuracy of the stator coils and bearings is improved, and torque ripples on the rotor are eliminated. It has the excellent effect of preventing the occurrence of such problems as much as possible.

[Brief explanation of drawings]

FIGS. 1 to 5 show an embodiment in which the present invention is applied to an axial gap type brushless motor. FIG. 1 is a longitudinal sectional view of the entire motor, and FIG. 3 is a perspective view of the winding core, FIG. 4 is a perspective view of the winding body, and FIG. 5 is a perspective view of the molded product.
FIG. 6 is a diagram corresponding to FIG. 5 showing another embodiment of the present invention, and FIG.
The figure is a diagram corresponding to FIG. 1 showing another example of application of the present invention. In the figure, 3 is a stator coil mold body, 4 is a stator coil, 6 is a bearing part, 8 is a stator, 12 is a rotating shaft, 15
17 is a strip-shaped copper plate (conductive plate), 17 is a winding body, 18 is a molded product, 19 and 20 are holes, 21 is a bearing member, and 24 is a rotating shaft. Applicant Toshiba Corporation Figure 1 Figure 2 Figure 5 Figure 7

Claims (1)

[Claims] 1. A stator coil formed by resin-molding a plurality of winding bodies made by winding conductive plates into a cylindrical shape and cutting the molded product across the winding bodies. Rotation of the rotor is formed integrally with the stator coil molded body by cutting an axially extending hole integrally formed in the molded product with a molded body and a resin mold of the winding body, together with the winding body. A stator comprising a bearing portion that supports a shaft. 2. The bearing part is formed by resin-molding a cylindrical bearing member having a hole together with a winding body, and then cutting the cylindrical bearing member across the resin mold, as set forth in claim 1. stator.