JPS6258855A - Stator - Google Patents

Abstract

PURPOSE:To improve characteristic and simplify the work of wiring, by cutting of a molded unit of a winding unit and a sheet-formed conducting unit integrated with each other to be resin-molded, in a desired thickness, and by obtaining a stator of a coil section and a conductor section for wiring integrated with each other to be molded. CONSTITUTION:Winding sections 22 formed by winding up conductive sheets in cylindrical shapes are arranged in ring shapes at specified intervals, and in parallel with the axial direction, the conductive sheets 23 for wiring made of conductive sheet material and pipe-formed connecting units 24 are relatively arranged at specified positions, and after that, the whole sections are integrally molded with resin to form a molded unit 25. the molded unit 25 is sliced in a specified thickness through a plane orthogonal to the axial direction. Then, sheet-formed stators are obtained respectively, from stator coils for the winding sections 22, from wiring conductive sections for the wiring conductive plate 23, and from connecting terminals for the connecting units 24.

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 background of the invention and its problems] Conventionally, for example, the stator of an axial gap type brushless motor has been manufactured by winding an insulated conductive wire into a predetermined shape on a substrate facing a U-mount equipped with permanent magnets. The structure was such that a plurality of winding bodies were arranged in an annular shape and each was fixed by adhesive.

However, the conventional structure described above has the drawback that it is not suitable for mass production, as it requires labor-intensive work such as winding insulated conductors to form stator coils and individually bonding these stator coils to the substrate. Ta. Furthermore, since a plurality of stator coils are individually arranged by adhesive bonding, the positional accuracy between the stator coils tends to be inconsistent, which has the disadvantage of causing 1 to 1 ripple ripples to occur in the rotor.

Therefore, in order to solve the above-mentioned drawbacks, the following configuration has been considered. That is, a plurality of winding bodies made by winding a band-shaped conductive plate into a cylindrical shape are arranged in an annular shape, these are molded with resin, and the molded product is cut across the winding body. This forms the molded body of the stator coil.

However, even in this case, it is necessary to separately form the wiring pattern of the control circuit that controls energization and disconnection to the stator coils on the wiring board, and this remains an issue that must be solved in order to dramatically improve mass productivity. It remained as it was.

[Object of the Invention] The present invention has been made in consideration of the above circumstances, and its purpose is to provide a stator that can sufficiently improve mass productivity and prevent torque ripples from occurring in the rotor as much as possible. It is on offer.

[Summary of the Invention] The stator of the present invention is an S? A winding body made by winding a ¥lf board into a cylindrical shape and a conductive plate for wiring made by forming a conductive plate into a predetermined shape are arranged in a predetermined position and molded with insulating resin, and the molding is performed. A stator formed by cutting the winding body into a mold body formed by cutting the molded product, the stator being formed by cutting the object so as to cross the winding body and the conductive plate for wiring. The coil and the wiring conductor part formed by cutting the wiring conductive plate are buried, so that the stator coil and the wiring conductor part are formed by cutting the molded product. It is possible to form molded bodies arranged at predetermined positions.

[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 the drawings.

First, in FIG. 2 showing the overall configuration, 1 is a stator yoke, and a bearing sleeve 2 is provided at the center of this stator yoke. Reference numeral 3 denotes a molded body attached to the stator yoke 1, which includes, for example, four stator coils 4 arranged in an annular area as shown in FIG. A circular hole 6 for inserting the bearing cylinder 2 is formed in the center, and a rectangular projecting part 7 is formed on the right side in the figure. Further, an annular copper connecting portion 8.9 is provided at the winding start end and winding end of each stator coil 4, respectively. 10 is an electronic component for configuring a control circuit that controls energization/disconnection to the stator coil 4; 11 is each electronic component 10;
The wiring conductor part connects between stator coils 4 and stator coils 4,
This is embedded in the mold body 3, and has an annular copper connecting portion 12 at its end. And mold body 3
The terminals of each electronic component 10 are inserted and soldered into the connecting portion 12 located on the overhanging portion 7 of the electronic component 10 . Further, the connection portion 8 on the winding start end side of the stator coil 4 is connected to the connection portion 12 of the wiring conductor portion 11 via a covered lead wire 13. For the stator 14 configured as above,
As shown in FIG. 2, the rotor 15 has a permanent magnet 17 attached to the inner surface of a rotor yoke 16 which is shaped like a flat circular container with an open bottom surface, and a rotating shaft 18 is fitted into the center of the rotor yoke 16. It is configured as follows. The rotating shaft 18 is rotatably inserted into and supported by the bearing sleeve 2 of the stator 1, and thereby the stator coil 4
The group and the permanent magnets 17 are arranged to face each other with a predetermined gap therebetween.

Next, a method for manufacturing the molded body 3 will be explained based on FIGS. 3 to 5. 19 is a strip-shaped conductive plate with an insulating layer (not shown) formed on one side; 20 is a hollow connecting body made of, for example, a copper vibrator; this connecting body 20 is connected to the conductive plate 1;
9 by, for example, soldering, the conductive plate 19 is wound around the connecting body 20 a plurality of times (see FIG. 4). At this time, the conductive plate 19 is wound while being coated with adhesive. After winding, a connecting body 21 made of, for example, a copper pipe is connected to the other end of the conductive plate 19 by soldering. As a result, a winding body 22 is constructed in which connecting bodies 20 and 21 extending in the axial direction are provided in an electrically connected state at the winding start end and winding end of the l electric plate 19.

On the other hand, a plurality of electrically conductive plates having a predetermined quality are each formed into a predetermined shape to constitute a plurality of 13 wiring boards 23 (see FIG. 5). Among these, connecting bodies 24 made of copper pipes are soldered to the ends of the wiring conductive plates 23 for connecting the terminals of the electronic components 10 and the coated lead wires 13, respectively, and the other wiring conductive plates 23 are soldered to the ends thereof. The end portion is connected to the connecting body 21 on the winding end side of the winding body 22.
solder to. After that, for example, the four winding bodies 22 and a predetermined number of wiring conductive plates 23 are housed in a mold (not shown), and the winding body 22 is formed into a substantially annular shape by the positioning line surface of the mold. At the same time, the wiring conductive plates 23 are arranged at predetermined positions. Then, after sealing both ends of each connecting body 20.degree. 21.24 with a mold to prevent the mold resin from entering the inside, the mold resin is injected into the mold and solidified. After the mold resin has solidified, the mold is opened and the molded product 25 is taken out from inside the mold, and this molded product 25 is then wrapped around the winding body 22, as shown by the broken line in FIG.
If the conductive plate 23 for wiring and the connecting bodies 20, 21, 24 are cut in a so-called round shape, the winding body 22
By cutting, four stator coils 4 are formed, and by cutting the wiring conductive plate 23, the wiring conductor part 11 is formed, and by cutting the connecting bodies 20, 21, 24, a connecting part 8.9° 12 is formed. is formed, thus molded product 2
By cutting 5, the stator coil 4. The molded body 3 in which the wiring conductor portion 11 and the connection portions 8, 9, and 12 are embedded is completed.

In that case, the terminals of each electronic component 10 are inserted into a predetermined connection part 12 and both are soldered, and the stator coil 4
The connection part 8 on the winding start end side and the connection part 12 of the predetermined wiring conductor part 11 are connected by soldering via the covered lead wire 13, and then the molded body 3 is attached to the stator yoke 1. Once fixed, the stator 14 is completed.

According to this embodiment, the following effects can be obtained. That is, the stator coil 4 and the wiring conductor part 11 are molded in resin with the winding body 22 and the wiring conductive plate 23 arranged at predetermined positions, and the molded product 25 is cut into circular slices. Since the structure is such that a molded body 3 is formed, there is no need to perform the labor-intensive work of winding the insulated conductor wires to form the stator coils and then individually bonding them to the substrate during manufacturing. There is no need to form a wiring pattern on the top, and the productivity is sufficiently improved. Moreover, since the winding body 22 in the molded product 25 is reliably positioned at an accurate position by the positioning function of the mold, the stator coil 4 is also inevitably positioned with high precision, and therefore the rotor 15 can be prevented as much as possible from occurring.

In addition, in this embodiment, connecting bodies 24 extending in the axial direction are provided at the ends of the winding body 22 and the ends of the wiring conductive plate 23, and by cutting the connecting bodies 24, the ends of the stator coil 4 and the wiring conductive plate 23 are provided with connecting bodies 24 extending in the axial direction. At the ends of the conductor section 11 there are connection sections 8, 9, . 12, there is no need to separately provide a connection part for connecting the terminals of the electronic component 10 to the mold body 3 after manufacturing the mold body 3, which further improves mass productivity. obtain.

In addition, the connecting bodies 20, 21, and 24 are formed into hollow shapes using copper vibrators, and the connecting parts 8, 9, and 9 are formed by cutting the connecting bodies 20, 21, and 24 into hollow shapes.
12 is configured to form an annular shape, the terminal of the electronic component 10 and the core wire at the end of the coated lead wire 13 can be inserted into the connecting portion 8, 9, and 12 and temporarily held during soldering. , these soldering operations can be performed efficiently.

In the above embodiment, the connecting body 20, 21, 24 is formed in a hollow shape so that the connecting part 8.9.12 is annular, but it is not always necessary to form it in this way. The connecting portion may be formed in a shape without holes. Further, the connection between the connection part 8 on the winding start end side of the stator coil 4 and the connection part 12 of the wiring conductor part 11 can be made without using the covered lead wire 13, for example, on the cut surface of the stator coil 4. A structure may be adopted in which a layer is formed and then connected using a bonding wire A7° conducting wire or the like. Further, in the above embodiment, a connecting body 20 (connecting part 9) is provided at the end of the winding of the winding body 22 (stator coil 4), and a wiring conductive plate 23 (wiring conductor part 11) is provided on this connecting body 20. Although the configuration is such that the ends are soldered, the present invention is not limited to this, and for example, the winding end portion of the winding body may be integrally extended and the extended portion may be used as a conductive plate for wiring. Furthermore, in the above embodiment, when manufacturing the winding body 22, the conductive plate 19 is wound while being coated with an adhesive, but the present invention is not limited to this. A conductive plate may be wound to form a winding body.

"Effects of the Invention" As is clear from the above description, the present invention is capable of producing a stator by molding a winding body and a wiring conductive plate in a predetermined position in a resin mold, and cutting the molded product into circular slices. Since the structure is such that a molded body is formed in which the coil and the wiring conductor are embedded, it is necessary to perform the labor-intensive work of winding the insulated conductor wire to form the stator coil and then gluing it individually to the board during manufacturing. Not only is there no need to form a wiring pattern on a separate board, mass productivity is sufficiently improved. Moreover, since the windings within the molded product are reliably positioned at accurate positions by the positioning function of the mold, the stator coils are also necessarily positioned with high precision, and therefore the rotor This has the excellent effect of preventing torque ripple as much as possible.

[Brief explanation of the drawing]

The drawings show an embodiment in which the present invention is applied to an axial gear V-tube type brushless motor. Fig. 1 is a plan view of the stator, Fig. 2 is a longitudinal cross-sectional view of the entire stator, and Fig. 3 is a diagram showing a conductive plate and a brushless motor. FIG. 4 is a perspective view of the connecting body, FIG. 4 is a perspective view of the winding body, and FIG. 5 is a perspective view of the molded product. In the drawing, 3 is a molded body, 4 is a stator coil, 8.9
is a connection part, 11 is a wiring conductor part, 12 is a connection part, 14 is a stator, 19 is a conductive plate, 20.21 is a connection body, 22 is a winding body, 23 is a conductive plate for wiring, 24 is a connection body, 25 is a molded product. Figure 1 Figure 3 Figure 2゜4th opening

Claims (1)

[Claims] 1. A winding body formed by winding a conductive plate into a cylindrical shape and a conductive plate for wiring formed by forming a conductive plate into a predetermined shape are arranged in a predetermined position and then wrapped with an insulating resin. The winding body is formed by molding, and the molded body is cut across the winding body and the conductive plate for wiring, and the winding body is cut into the mold body formed by cutting the mold body. A stator characterized in that a stator coil formed by cutting the wiring conductive plate and a wiring conductor portion formed by cutting the wiring conductive plate are embedded. 2. It should be noted that the ends of the stator coil and the ends of the wiring conductor are provided with connections formed by cutting the connections provided at the ends of the winding and the ends of the wiring. A stator according to claim 1. 3. The stator according to claim 2, wherein the connecting body is formed in a hollow shape.