JPWO2020085158A1 - Manufacturing method of insulating structure of rotary electric machine and insulating structure of rotary electric machine - Google Patents

Abstract

A laminated iron core (5) formed by laminating steel plates is provided, and a resin insulating portion (6) is formed on the laminated iron core (5) so as to cover at least the surface portion where the coil (4) is wound. In the insulating structure of the rotating electric machine, the resin insulating portion (6) is thickened in the circumferential direction (R) on the central side of both end faces along the axial direction (X) of the laminated iron core (5). A bulging portion (6d) is provided so as to be.

Description

The present application relates to an insulating structure of a rotary electric machine and a method of manufacturing an insulating structure of a rotary electric machine.

Conventionally, a coil is wound around a laminated iron core formed by laminating a plurality of steel plates obtained by punching an electromagnetic steel plate with a press mold, and a resin made of an insulating resin for preventing electrical conduction between the coil and the laminated iron core. An insulating structure such as a rotor or a stator of a rotary electric machine formed by integrally molding an insulating portion is known (see, for example, Patent Document 1 below).

Japanese Unexamined Patent Publication No. 8-98473

In the case of integrally molding a resin insulating portion made of an insulating resin in an insulating structure of a rotor or a stator of a rotary electric machine as described in Patent Document 1, an insulating resin is molded into a molding mold by using an injection molding method. When filling the resin, a loss of filling pressure occurs due to an increase in flow resistance such as thickening and hardening of the insulating resin. This pressure loss becomes large especially at the resin flow end portion of the insulating resin, and there is a problem that the insulating resin cannot be sufficiently filled or the electrical insulation performance is deteriorated.

As a countermeasure, it is conceivable to newly mix a material of an insulating resin having good fluidity to suppress a decrease in pressure loss when filling the molding die. However, such a highly fluid insulating resin has a problem that it becomes expensive because it is necessary to specially prepare a material, and the manufacturing cost of a rotary electric machine increases.

In addition, as another measure, it is conceivable to set a large gap between the laminated iron core and the molding die to suppress the loss of filling pressure at the resin flow end of the insulating resin when filling the insulating resin. Be done. However, when the gap between the laminated iron core and the molding die is set large in this way, as a result, the wall thickness of the insulating resin covering the laminated iron core becomes large, and the coil is wound around the laminated iron core. There is a problem that the area that can be rotated becomes smaller and the performance of the rotating electric machine deteriorates.

The present application has been made to solve the above-mentioned problems, and the insulating structure of a rotating electric machine having a small size, high efficiency, and insulating performance without causing an extra cost increase or performance deterioration. An object of the present invention is to provide a method for manufacturing an insulating structure of a rotary electric machine.

The insulating structure of a rotary electric machine disclosed in the present application is
In an insulating structure of a rotating electric machine, which is provided with a laminated iron core in which a plurality of steel plates are laminated, and a resin insulating portion is integrally formed on the laminated iron core by at least covering the surface portion of a portion where a coil is wound. ,
The resin insulating portion includes a bulging portion formed thickly in the circumferential direction on the central side of both end surfaces along the axial direction of the laminated iron core.
Further, the insulating structure of the rotary electric machine disclosed in the present application is:
Insulation of a rotary electric machine is provided with a laminated iron core in which a plurality of steel plates are laminated, and a resin insulating portion covering at least the surface portion of a portion where a coil is wound is assembled from two or more axial directions on the laminated iron core. In the structure
In the resin insulating portion, the maximum thickness of the portion formed on the axial end face of the laminated iron core is thicker than the maximum thickness of the portion formed along the axial direction of the laminated iron core, and the laminated iron core is formed. Has a resin injection port mark on the end face in the axial direction of
In the resin insulating portion, the thickness of the portion where the end face in the axial direction of the laminated iron core is formed is uniformly formed.
The resin insulating portion is formed to be thicker in the circumferential direction on the central side than both end faces along the axial direction of the laminated iron core.
Further, the method for manufacturing an insulating structure of a rotary electric machine disclosed in the present application is described.
A method of manufacturing an insulating structure of a rotary electric machine, which is provided with a laminated iron core formed by laminating steel plates, and in which a resin insulating portion is integrally formed by covering at least the surface portion of a portion where a coil is wound. There,
A molding die for injection molding of the resin insulating portion is applied, and the inner wall of the molding die has a wall thickness in the circumferential direction on the central side of both end faces along the axial direction of the laminated iron core. A recess for forming a bulging portion is formed in advance, the laminated iron core is arranged inside the molding die, and then an insulating resin is injected from the resin injection port of the molding die to form the resin insulating portion. Is to be molded.
Further, the method for manufacturing an insulating structure of a rotary electric machine disclosed in the present application is described.
Insulation of a rotary electric machine is provided with a laminated iron core in which a plurality of steel plates are laminated, and a resin insulating portion covering at least a surface portion where a coil is wound is assembled from two or more axial directions on the laminated iron core. It is a method of manufacturing a structure.
A molding mold for injection molding in which the resin insulating portion is divided into two or more directions in the axial direction is applied, and the inner wall of the mold of the molding mold is on the center side of both end faces along the axial direction of the laminated iron core. In the above, a concave portion for forming a bulging portion that becomes thicker in the circumferential direction was formed in advance, and an insulating resin was injected from the resin injection port of the molding mold to be divided into two or more directions in the axial direction. After molding the resin insulating portion and taking out the resin insulating portion divided into two or more directions in the axial direction from the molding mold, the resin insulating portion divided into two or more axial directions in the laminated iron core. Is assembled from two or more axial directions.

According to the method for manufacturing the insulating structure of the rotating electric machine and the insulating structure of the rotating electric machine of the present application,
It is possible to have small size, high efficiency, and insulation performance without causing an extra cost increase or performance decrease.

It is a perspective view which shows 6 teeth part which is a half circumference part when it is applied to a stator as the insulating structure of the rotary electric machine of Embodiment 1. FIG. It is a perspective view which shows one of the split stators which make up the stator of FIG. It is a perspective view which shows the insulation division iron core which comprises the division stator of FIG. It is a front view which looked at the insulation division iron core of FIG. 3 from the radial direction. It is a perspective view when the insulation division iron core of FIG. 4 is cut along the line AA. It is a perspective view which shows the laminated iron core which comprises the insulation division iron core of FIG. It is sectional drawing which shows the state which the coil is wound around the insulation division iron core in Embodiment 1. FIG. It is sectional drawing which shows the state which the coil is wound on the insulation division iron core in the comparative technique 1. It is a flowchart which shows the process of the manufacturing method of the stator in Embodiment 1. It is explanatory drawing which shows the procedure in the case of injection molding the resin insulating part into the laminated iron core by using the molding die in Embodiment 1. FIG. It is explanatory drawing which shows the procedure in the case of injection molding the resin insulating part into the laminated iron core by using the molding die in Embodiment 1. FIG. It is explanatory drawing which shows the procedure in the case of injection molding the resin insulating part into the laminated iron core by using the molding die in Embodiment 1. FIG. It is explanatory drawing which shows the procedure in the case of injection molding the resin insulating part into the laminated iron core by using the molding die in Embodiment 1. FIG. It is explanatory drawing which shows the procedure in the case of injection molding the resin insulating part into the laminated iron core by using the molding die in Embodiment 1. FIG. It is explanatory drawing which shows the procedure in the case of injection molding the resin insulating part into the laminated iron core by using the molding die in Embodiment 1. FIG. FIG. 5 is a partially enlarged cross-sectional view of the case where the insulating resin is injected into the laminated iron core using the molding die in the first embodiment. It is explanatory drawing which shows the flow state of the insulating resin at the time of injecting the insulating resin into a laminated iron core by using the molding die in Embodiment 1. FIG. It is explanatory drawing of the flow resistance generated in the insulating resin when the insulating resin is injected using the molding die. FIG. 5 is a partially enlarged cross-sectional view of a case where an insulating resin is injected into a laminated iron core using a molding die in Comparative Technique 2. FIG. 5 is a cross-sectional view showing a modified example of a bulging portion of a resin insulating portion formed on a laminated iron core in the first embodiment together with a state in which a coil is wound. FIG. 5 is a cross-sectional view showing a state in which a coil is wound around another modified example of a bulging portion of a resin insulating portion formed on a laminated iron core in the first embodiment. It is a perspective view when it is applied to a rotor as an insulating structure of the rotary electric machine of Embodiment 2. FIG. 5 is an exploded perspective view showing an insulated iron core and a shaft constituting the rotor of FIG. It is a top view of the rotor of FIG. It is a perspective view when the rotor of FIG. 19 is cut along the line BB. It is a perspective view which shows the laminated iron core which constitutes the insulating iron core of the stator of FIG. FIG. 5 is a cross-sectional view showing a state in which a coil is wound on an insulated iron core in the second embodiment. It is sectional drawing which shows the state which the coil is wound on the insulated iron core in the comparative technique 3. It is a flowchart which shows the process of the manufacturing method of the rotor in Embodiment 2. It is explanatory drawing which shows the procedure in the case of injection molding the resin insulating part for each laminated iron core by using the molding die in Embodiment 2. It is explanatory drawing which shows the procedure in the case of injection molding the resin insulating part for each laminated iron core by using the molding die in Embodiment 2. It is explanatory drawing which shows the procedure in the case of injection molding the resin insulating part for each laminated iron core by using the molding die in Embodiment 2. It is explanatory drawing which shows the procedure in the case of injection molding the resin insulating part for each laminated iron core by using the molding die in Embodiment 2. It is explanatory drawing which shows the procedure in the case of injection molding the resin insulating part for each laminated iron core by using the molding die in Embodiment 2. It is explanatory drawing which shows the procedure in the case of injection molding the resin insulating part for each laminated iron core by using the molding die in Embodiment 2. FIG. 5 is a partially enlarged cross-sectional view of the case where the insulating resin is injected into the laminated iron core using the molding die in the second embodiment. It is explanatory drawing which shows the flow state of the insulating resin at the time of injecting the insulating resin into a laminated iron core by using the molding die in Embodiment 2. FIG. FIG. 5 is a partially enlarged cross-sectional view of a case where an insulating resin is injected into a laminated iron core using a molding die in Comparative Technique 4. FIG. 5 is a cross-sectional view showing a modified example of a bulging portion of a resin insulating portion formed on a laminated iron core in the second embodiment together with a state in which a coil is wound. FIG. 5 is a cross-sectional view showing a state in which a coil is wound around another modification of the bulging portion of the resin insulating portion formed on the laminated iron core in the second embodiment. It is sectional drawing which shows the modification of the laminated iron core in which the resin insulating part is integrally formed in Embodiment 2. FIG. FIG. 5 is a cross-sectional view showing another modified example of the laminated iron core in which the resin insulating portion is integrally formed according to the second embodiment. FIG. 5 is a cross-sectional view showing another modified example of the laminated iron core in which the resin insulating portion is integrally formed according to the second embodiment. It is a perspective view which shows 6 teeth part which is a half circumference part when it is applied to a stator as an insulating structure of the rotary electric machine of Embodiment 3. It is a perspective view which shows one of the split stators constituting the stator of FIG. 34. It is a perspective view which shows the insulation division iron core which comprises the division stator of FIG. 35. It is a front view which looked at the insulation division iron core of FIG. 36 from the radial direction. It is a perspective view when the insulation division iron core of FIG. 37 is cut along the CC line. It is a perspective view which shows the laminated iron core which comprises the insulation division iron core of FIG. 36. It is sectional drawing which shows the state which the coil is wound on the insulating division iron core in Embodiment 3. It is sectional drawing which shows the state which the coil is wound on the insulating division iron core in the comparative technique 5. It is a flowchart which shows the process of the manufacturing method of the rotor in Embodiment 3. It is explanatory drawing which shows the procedure of assembling the insulating structure of the rotary electric machine in Embodiment 3. FIG. It is explanatory drawing which shows the procedure of assembling the insulating structure of the rotary electric machine in Embodiment 3. FIG. It is explanatory drawing which shows the procedure of assembling the insulating structure of the rotary electric machine in Embodiment 3. FIG. It is explanatory drawing which shows the procedure in the case of injection molding a resin insulating part using a molding die in Embodiment 3. It is explanatory drawing which shows the procedure in the case of injection molding a resin insulating part using a molding die in Embodiment 3. It is explanatory drawing which shows the procedure in the case of injection molding a resin insulating part using a molding die in Embodiment 3. It is explanatory drawing which shows the procedure in the case of injection molding a resin insulating part using a molding die in Embodiment 3. It is explanatory drawing which shows the procedure in the case of injection molding a resin insulating part using a molding die in Embodiment 3. FIG. 5 is a partially enlarged cross-sectional view of the case where the resin insulating portion is injection-molded using a molding die in the third embodiment. It is explanatory drawing which shows the flow state of the insulating resin at the time of injecting the insulating resin by using the molding die in Embodiment 3. FIG. It is sectional drawing which shows the structure of the insulation division iron core in the comparative technique 6. FIG. 5 is a cross-sectional view showing a modified example of a bulging portion of a resin insulating portion assembled on a laminated iron core in the third embodiment together with a state in which a coil is wound. FIG. 5 is a cross-sectional view showing a state in which a coil is wound around another modified example of a bulging portion of a resin insulating portion assembled on a laminated iron core in the third embodiment.

Embodiment 1.
FIG. 1 is a perspective view showing six teeth, which is a half circumference when applied to a stator as an insulating structure of a rotary electric machine according to the first embodiment of the present application, and FIG. 2 constitutes the stator of FIG. A perspective view showing one of the split stators, FIG. 3 is a perspective view showing an insulating split iron core constituting the split stator of FIG. 2. Further, FIG. 4 is a front view of the insulated split iron core of FIG. 3 viewed from the circumferential direction, and FIG. 5 is a perspective view of the insulated split iron core of FIG. 4 cut along the line AA. Further, FIG. 6 is a perspective view of the laminated iron core constituting the insulated divided iron core of FIG. 3, and FIG. 7 is a cross-sectional view showing a state in which a coil is wound around the insulated divided iron core in the first embodiment. Here, it is assumed that the axial direction of the stator or the split stator is indicated by reference numeral X, the radial direction is indicated by reference numeral D, and the circumferential direction is indicated by reference numeral R.

The stator 1 of the first embodiment is configured by connecting and arranging twelve teeth-split stators 2 in an annular shape along the circumferential direction R of the rotary electric machine. In this case, each of the split stators 2 is composed of an insulating split iron core 3 and a coil 4. The coil 4 is formed by winding a conductor such as a copper electric wire or an aluminum electric wire around an insulating divided iron core 3 a desired number of times. Although the number of teeth is set to 12 here, the number is not limited to this, and it can be arbitrarily designed according to the performance and structure of the rotary electric machine.

As shown in FIGS. 3 to 5, the insulating divided iron core 3 includes a laminated iron core 5 and a resin insulating portion 6.
Here, as shown in FIG. 6, the laminated iron core 5 is formed by laminating a predetermined number of steel sheets made of an electromagnetic steel sheet or a silicon steel sheet having a thickness dimension of about 0.1 mm to 3.0 mm in accordance with a desired axial length dimension L0. It is composed of. The laminated iron core 5 has a back yoke portion 5a that extends in a fan shape in a plan view along the circumferential direction R, a teeth portion 5b that protrudes from the back yoke portion 5a toward the center of the stator 1, and a circumferential direction from the teeth portion 5b. It has a protruding portion 5c extending along R.

Further, the resin insulating portion 6 includes, for example, PPS (PolyPheneylene Sulfide), LCP (Liquid Crystal Polymer), PBT (Polybutylene terephthalate), POM (Polyoxymethylene), PET (Polythethylene) It is integrally molded with the laminated iron core 5 by injection molding using a thermoplastic resin such as, or an epoxy resin, or a thermosetting resin such as BMC (Bulk Molding Compound) or SMC (Sheet Molding Compound).

That is, the resin insulating portion 6 is formed so as to cover the teeth portion 5b of the laminated iron core 5, both end faces of the back yoke portion 5a in the axial direction X, and both end faces of the protruding portion 5c in the axial direction X, respectively. Specifically, the resin insulating portions covering both end faces of the back yoke portion 5a and the protruding portion 5c in the axial direction X have flange portions 6a protruding from the axial end faces of the laminated iron core 5 by a predetermined length L1 respectively. It is formed as 6b. Each of the flange portions 6a and 6b is set so as to reliably maintain the insulated state of the coil 4 by projecting further in the axial direction X than the winding position of the coil 4.

Further, the resin insulating portion covering the surface of the teeth portion 5b around which the coil 4 is wound covers the end face winding portions 6c formed by covering both end faces of the teeth portion 5b in the axial direction X and the circumference of the teeth portion 5b. It is composed of a side winding portion 6d formed so as to cover a side surface portion extending along the axial direction X facing the direction R. The side winding portion 6d avoids interference between the coil wound around the own teeth portion and the coil of the other teeth portion adjacent to the circumferential direction R, and improves the coil space factor of the coil wound around the own teeth portion. Therefore, it is desired to form the thickness thin and long in the axial direction X. The end face winding portion 6c is configured so as not to impair the minimum bending radius of the conductor forming the coil 4, and the thickness thereof is as shown in FIG. 7 (maximum thickness T1 of the end face winding portion 6c). > (Maximum thickness W2 of the side winding portion 6d). The resin insulating portion 6 is provided with a resin injection port mark at a portion formed on the end face of the laminated iron core 5 in the axial direction X.

In this way, the resin insulating portion 6 (that is, the end face winding portion 6c and the side winding portion 6d) is formed by covering the surface portion of the teeth portion 5b around which at least the coil 4 of the laminated iron core 5 is wound. The insulating split iron core 3 and the coil 4 are electrically insulated so that the required characteristics of the rotary electric machine can be exhibited.

Further, in the case of the first embodiment (see FIG. 7), the thickness T1 of the end face winding portion 6c is uniform over the entire surface, but the thickness of the side winding portion 6d is the thickness of both end faces along the axial direction X. It is formed as a bulging portion so that the thickness W2 in the circumferential direction R becomes the wall thickness on the central side of the thickness W1. Therefore, the thickness T1 described above is the maximum thickness T1 of the end face winding portion 6c, and the thickness W2 is the maximum thickness W2 of the side winding portion 6d. That is, the bulging portion 6d, which is the side winding portion in this case, is formed in a semi-spindle shape so that the thickness gradually decreases toward both end faces with the center of the axial direction X as the apex. Moreover, in this case, as shown in FIG. 7, the bulging portion 6d is the coil 4 with reference to the surface of the teeth portion 5b facing the circumferential direction R when the coil 4 is wound on the bulging portion 6d. It is formed so as to bulge in the circumferential direction R within a range smaller than the winding swelling gap G1 generated between the two.

When forming a coil 4 by winding conductors such as copper electric wires and aluminum electric wires, which are elastic bodies, around an end face winding portion 6c and a side winding portion 6d covering the surface portion of the tooth portion 5b of the laminated iron core 5. Due to the elasticity of the conductor, it cannot be wound in a straight line, and is bulged and arranged in an arc shape at the end face winding portion 6c and the side winding portion 6d. Therefore, as shown in FIG. 7, a winding swelling gap G1 is generated between the teeth portion 5b and the coil 4 with reference to the surface facing the circumferential direction R. In the first embodiment, as described above. Since the bulging portion 6d as the side winding portion is formed so as to bulge in the circumferential direction R within a range smaller than the winding bulging gap G1, the thickness of the bulging portion 6d in the circumferential direction R It is not necessary to reduce the number of turns of the coil 4 to be wound while ensuring the insulating property by making the coil 4 as large as possible. That is, even if the bulging portion 6d is formed, the coil space factor of the coil 4 is not lowered. Therefore, the insulation function can be improved without significantly deteriorating the performance of the rotary electric machine, and an efficient rotary electric machine can be obtained.

On the other hand, in the case of the comparative technique 1 shown in FIG. 8, among the resin insulating portions 6 covering the surface portion of the teeth portion 5b of the laminated iron core 5, particularly the side winding portion 606d is directed toward the circumferential direction R. It is not formed to bulge, and the thickness along the axial direction X is formed as a uniform flat portion.

As described above, in the case of the comparative technique 1 shown in FIG. 8, since the thickness of the side winding portion 606d in the circumferential direction R is thin and uniform along the axial direction X, the coil 4 and the laminated iron core 5 are electrically insulated. The ability to do is reduced. As a countermeasure, if the thickness of the side winding portion 606d is set to be uniformly large, the deterioration of the insulating function can be prevented, but the number of turns of the coil 4 to be wound is reduced, and the performance of the rotary electric machine is deteriorated. In the case of the present application, such inconvenience due to the comparison technique 1 does not occur.

Next, the manufacturing process of the stator 1 of the rotary electric machine shown in FIG. 1 will be described.
FIG. 9 is a flowchart showing the process of the stator manufacturing method according to the first embodiment of the present application, and FIGS. 10A to 10F show a procedure in the case of injection molding a resin insulating portion for each laminated iron core using a molding die. FIG. 11 is a partially enlarged sectional view when the insulating resin is injected into the laminated iron core using a molding die, and FIG. 12 is an insulating resin when the insulating resin is injected into the laminated iron core using a molding die. It is explanatory drawing which shows the flow state of.

As shown in the flowchart of FIG. 9, first, a plurality of laminated iron cores 5 shown in FIG. 10A (FIG. 6) are formed by press-molding and laminating steel plates. Then, the laminated iron core 5 shown in FIG. 10A is positioned and fixed in the molding die 7 (FIGS. 10B and 10C). After that, an insulating resin is injection-molded in the molding die 7 to form the insulating split iron core 3 shown in FIG. 3 in which the resin insulating portion 6 is integrally formed with the laminated iron core 5 (FIG. 10D). After the injection molding is completed, the insulating split iron core 3 is separated from the molding die 7 (FIG. 10E), and the unnecessary resin portion is removed (FIG. 10F). At this time, a resin injection port mark remains. Next, a conductor is wound around the insulating split iron core 3 to form a coil 4, and the split stator 2 shown in FIG. 2 is formed. Then, the stator 1 is configured by connecting and arranging a predetermined number of the dividing stators 2 in an annular shape along the circumferential direction R.

Here, a method for injection molding the resin insulating portion 6 for each laminated iron core 5 will be described in more detail.

As shown in FIGS. 10B and 10C, first, the laminated iron core 5 shown in FIG. 10A (FIG. 6) is placed in the molding die 7, positioned, and fixed. The molding die 7 includes a mold inner wall 7a for sealing the back yoke portion 5a, the teeth portion 5b, and the protruding portion 5c of the laminated iron core 5, and a resin injection port 7b provided on each of the upper and lower flat end faces in the axial direction X. And have.

In particular, the molding die 7 applied to the first embodiment is side-wound on the side surface in the axial direction X for the purpose of improving the coil space factor, as shown in FIGS. 10B to 10E and 11. It has a cavity for forming the mounting portion 6d and a cavity for forming the end face winding portion 6c on the end face in the axial direction in order to secure the minimum bending radius of the conductor forming the coil 4. A recess 7d for forming a bulging portion 6d having a wall thickness in the circumferential direction is formed in advance on the central side of both end faces along the axial direction X of the laminated iron core 5. Further, as shown in FIG. 12, the resin injection port 7b is arbitrarily provided at a position where, for example, the flange portion 6b or the end face winding portion 6c of the resin insulating portion 6 is formed, and the insulating resin is provided from the resin injection port 7b. Infused.

The arrows in FIG. 12 indicate, for example, the flow direction when the insulating resin is injected from the upper and lower resin injection ports 7b. The injected insulating resin flows through the cavity, which is the space between the inner wall 7a of the mold and the laminated iron core 5, and is cured after filling, so that the resin insulating portion 6 integrated to cover the laminated iron core 5 is formed. It is formed. Therefore, in the case of FIG. 12, since the insulating resin is injected from each resin injection port 7b, it flows into the cavity along the axial direction X of the laminated iron core 5, and the central portion in the axial direction X becomes the resin flow end portion E1. Become.

In the process of the insulating resin flowing in the cavity between the laminated iron core 5 and the inner wall 7a of the mold, it receives a pressure loss due to flow resistance. Here, as shown in FIG. 13, the flow path depth in the cavity is M, the flow path width is N, the flow path length is L, the proportional multiplier is K, the flow rate is Q, and the starting end for injecting the insulating resin. The pressure loss ΔP (= Pin-Pout) is expressed by the following (Equation 1), where Pin is the pressure of and Pout is the end pressure.

ΔP = (12 × K × L × Q) / (N × M ³ ) (Equation 1)

As can be seen from the above (Equation 1), the smaller the flow path depth M of the cavity in the flow path cross section of the insulating resin, the larger the flow resistance and the larger the pressure loss ΔP. That is, when the insulating resin flows through the cavity, if the flow path depth M in the cavity is small, the pressure loss ΔP from the resin injection port 7b shown in FIG. 12 to the resin flow end portion E1 becomes large. The pressure tends to be insufficient at the resin flow end portion E1. When the pressure is insufficient at the resin flow end portion E1, the flow of the insulating resin is stopped, resulting in poor filling of the insulating resin and deterioration of the insulating function. From the result after the resin insulating portion 6 is formed on the laminated iron core 5, the thinner the thickness of the resin insulating portion 6 (corresponding to the flow path depth M), the poorer the filling of the insulating resin. This means that the insulation function is likely to deteriorate.

In the case of the first embodiment, as shown in FIGS. 10A to 10F and 11 (see FIG. 7), the molding die 7 has a resin flow end portion E1 of the insulating resin of the resin insulating portion 6. Along the axial direction X, the side winding of FIG. 7 after forming the resin insulating portion 6 is located on the center side of both end surfaces (corresponding to the portion of the thickness W1 of the side winding portion 6d of FIG. 7 after forming the resin insulating portion 6). A recess 7d for forming a bulging portion, which becomes thicker in the circumferential direction R, is formed in advance in the portion 6d having a thickness W2). Therefore, since the flow path depth M of the cavity gradually increases from the resin injection port 7b to the resin flow end portion E1, the decrease in the pressure loss ΔP is suppressed. As a result, poor filling at the resin flow end portion E1 can be prevented, and the insulating function can be improved.

Then, even if the resin injection port 7b is arranged in the vicinity of the side winding portion 6d having a thin wall thickness W1 such as both end faces along the axial direction X, the pressure loss shown above (Equation 1) causes , The insulating resin easily flows to the end face winding portion 6c, the flange portion 6a on the back yoke portion 5a, and the flange portion 6b on the protruding portion 5c, and the side winding portion 6d becomes the resin flow end portion E1 of the insulating resin. Become.

On the other hand, in the case of the comparative technique 2 shown in FIG. 14, the recess 7d for forming the bulging portion, which becomes thicker in the circumferential direction as in the first embodiment of the present application, is not formed. Since the mold inner wall 607a is formed in which the flow path depth M in the cavity becomes thin and uniform along the axial direction X, the pressure loss ΔP increases from the resin injection port 7b to the resin flow end portion, and insulation is provided. The flow of the resin for use stops, and poor resin filling and deterioration of the insulating function are likely to occur.

As described above, in the first embodiment, the resin insulating portion 6 integrated with the laminated iron core 5 is provided in the circumferential direction on the central side of the thickness W1 of both end surfaces along the axial direction X of the laminated iron core 5. Since the bulging portion 6d having a wall thickness W2 toward R is formed, the pressure loss ΔP due to the increase in flow resistance when the insulating resin is injection-molded using the molding die 7. Can be reduced, and the filling property of the insulating resin and the insulating performance can be improved.

Moreover, the center of the coil 4 to be wound swells due to elastic deformation, but the bulging portion 6d of the resin insulating portion 6 has a thickness in the circumferential direction R on the center side of the thickness W1 of both end faces thereof. Since W2 is formed to be thick, the gap between the coil 4 and the bulging portion 6d becomes small, and the number of turns of the coil 4 to be wound is not reduced, and the coil 4 is occupied. The decrease in the rate is suppressed. Therefore, the insulation function can be improved without deteriorating the performance of the rotary electric machine, and it is possible to provide an insulating structure of the rotary electric machine having a small size, high efficiency, and sufficient insulation performance.

Further, since it is not necessary to select an expensive insulating resin having good fluidity and it is not necessary to locally heat the molding die 7 in order to improve the fluidity of the insulating resin, the material cost and equipment By controlling the cost, it is possible to provide an inexpensive rotary electric machine.

By the way, as shown in FIGS. 10A to 10F and 11, when resin injection ports 7b are provided at both ends of the molding die 7 in the axial direction X, the resin flow end portion E1 is in the axial direction of the side winding portion 6d. Although it is formed in the central portion along X, the flow of the insulating resin and the position of the resin flow end portion E1 change depending on the shape of the resin insulating portion 6.

Therefore, the bulging portion 6d of the resin insulating portion 6 is formed in a semi-spindle shape so as to have a wall thickness of a thickness W2 gradually in the circumferential direction R from the thickness W1 of both end surfaces thereof along the axial direction X. For example, as shown in FIG. 15, a cross section having a thickness W2 in the circumferential direction R on the central side of the thickness W1 of both end faces thereof is formed in a trapezoidal shape along the axial direction X. As shown in FIG. 16 or the bulging portion 6d, a cross section having a thickness W2 in the circumferential direction R is formed in a protruding shape on the central side of the thickness W1 of both end surfaces thereof along the axial direction X. By changing the shape of the recess 7d of the molding die 7 so that the formed bulging portion 6d is formed, the increase in flow resistance when injection molding the insulating resin using the molding die 7 is locally increased. It is possible to improve the insulation function by suppressing the target.

Further, when the resin injection port 7b of the molding die 7 is provided at only one place on one side in the axial direction X, for example, the resin flow end portion E1 is at the center of the side winding portion (bulging portion) 6d in the axial direction X. It may shift from the position. Also in that case, the position of the bulging portion 6d having a trapezoidal cross section shown in FIG. 15 or the bulging portion 6d having a protruding cross section shown in FIG. 16 is appropriately positioned from the central position in the axial direction X. By forming them in a staggered manner, the same effect of improving the insulating function can be obtained.

The insulating structure of the rotary electric machine according to the first embodiment is of various rotary electric machines for servo motors, fuel injection valve opening / closing timing control units, air conditioning fan motors, in-vehicle fuel pump units, hoisting machines, and the like. It can be applied to stators.

According to the insulating structure of the rotary electric machine of the first embodiment configured as described above,
In an insulating structure of a rotating electric machine, which is provided with a laminated iron core in which a plurality of steel plates are laminated, and a resin insulating portion is integrally formed on the laminated iron core by at least covering the surface portion of a portion where a coil is wound. ,
Since the resin insulating portion includes a bulging portion formed thickly in the circumferential direction on the central side of both end faces along the axial direction of the laminated iron core, the resin insulating portion includes a bulging portion.
Further, according to the manufacturing method of the insulating structure of the rotary electric machine,
A method for manufacturing an insulating structure of a rotating electric machine, which is provided with a laminated iron core formed by laminating steel plates, and a resin insulating portion is integrally formed on the laminated iron core by at least covering the surface portion of a portion where a coil is wound. There,
A molding die for injection molding of the resin insulating portion is applied, and the inner wall of the molding die has a wall thickness in the circumferential direction on the central side of both end faces along the axial direction of the laminated iron core. A recess for forming a bulging portion is formed in advance, the laminated iron core is arranged inside the molding die, and then an insulating resin is injected from the resin injection port of the molding die to form the resin insulating portion. Because it molds
The central portion of the wound coil in the axial direction swells due to elastic deformation, but the bulging portion is formed so as to become thicker in the circumferential direction on the central side than both end faces in the axial direction. Therefore, the insulation performance can be improved without lowering the coil space factor of the coil, and an insulating structure of a small rotary electric machine, and eventually a rotary electric machine can be obtained with the same performance. Further, by reducing the air layer between the coil and the resin insulating portion, the efficiency of transmitting the heat generated by the coil to the laminated iron core is improved, so that the conventional structure does not cause an extra cost increase or performance deterioration. It is possible to obtain an insulating structure of a rotating electric machine having the same size, high efficiency, and reduced heat dissipation parts, and by extension, a rotating electric machine.
Further, the inner wall of the die of the molding die is formed by preliminarily forming a recess for forming a bulging portion which becomes thicker in the circumferential direction on the central side than both end faces along the axial direction of the laminated iron core. After arranging the laminated iron core inside the mold, the insulating resin is injected from the resin injection port of the molding mold.
It is possible to reduce the pressure loss caused by the increase in the flow resistance when filling the insulating resin. Therefore, since the filling property of the insulating resin is improved, it is not necessary to select an expensive insulating resin having good fluidity, and local heating of the molding die is performed in order to improve the fluidity of the insulating resin. Since there is no need to do so, material costs and equipment costs can be suppressed, and an inexpensive insulating structure for a rotating electric machine, and thus a rotating electric machine can be provided.

Further, in the resin insulating portion, the maximum thickness of the portion formed on the axial end face of the laminated iron core is thicker than the maximum thickness of the portion formed along the axial direction of the laminated iron core, and the said. Since the resin injection port mark is provided at the position formed on the axial end face of the laminated iron core,
The filling property of the insulating resin can be further improved.

Further, in the resin insulating portion, the thickness of the portion where the end face in the axial direction of the laminated iron core is formed is uniformly formed.
Insulation between the resin insulating portion and the coil can be ensured at both ends of the laminated iron core in the axial direction.

Further, since the bulging portion is provided within a range smaller than the winding bulging gap between the laminated iron core and the coil, the bulging portion is formed.
The bulging portion can surely improve the insulation performance without surely lowering the coil space factor of the coil, and can surely obtain a small rotary electric machine with the same performance. In addition, by reliably reducing the air layer between the coil and the resin insulating part, the efficiency of transmitting heat generated by the coil to the laminated iron core is surely improved, resulting in an extra cost increase or performance decrease compared to the conventional structure. It is possible to surely obtain an insulating structure of a rotating electric machine having the same size, high efficiency, and reduced heat dissipation parts, and by extension, a rotating electric machine without inviting.

Further, since the bulging portion is formed at a portion corresponding to the tooth side surface portion facing the laminated iron core in the circumferential direction, the bulging portion is formed.
The bulging portion can be easily formed.

Further, since the bulging portion has a semi-spindle-shaped cross section whose thickness gradually decreases toward both end faces with the center in the axial direction as the apex.
The filling property of the insulating resin can be further improved.

Further, since the bulging portion has a trapezoidal cross section,
The bulging portion can be easily formed.

Further, since the cross section of the bulging portion is formed in a protruding shape,
The bulging portion can be easily formed.

Embodiment 2.
17 is a perspective view when applied to a rotor as an insulating structure of a rotary electric machine according to a second embodiment of the present application, FIG. 18 is an exploded perspective view showing an insulating iron core and a shaft constituting the rotor, and FIG. 19 is FIG. 17 20 is a perspective view of the rotor of FIG. 19 when the rotor of FIG. 19 is cut along the line BB. 21 is a perspective view of a laminated iron core constituting the insulating iron core of the stator of FIG. 17, and FIG. 22 is a cross-sectional view showing a state in which a coil is wound on the insulated iron core in the second embodiment. Here, it is assumed that the axial direction of the rotor and the insulating iron core is indicated by reference numeral X, the radial direction is indicated by reference numeral D, and the circumferential direction is indicated by reference numeral R.

The rotor 11 of the second embodiment includes a shaft 12 that serves as a rotation shaft of a rotary electric machine, an insulated iron core 13, and a coil (not shown) wound around the insulated iron core 13. Although the case where the number of teeth of the insulating iron core 13 is four is shown here, the number of teeth is not limited to this, and the number of teeth can be arbitrarily designed according to the performance and structure of the rotary electric machine. Further, the wound coil (not shown) can be arbitrarily designed according to the performance and structure of the rotary electric machine, such as winding a copper electric wire, an aluminum electric wire, etc., which are conductors, a desired number of times.

The insulating iron core 13 includes a laminated iron core 15 and a resin insulating portion 16.
Here, as shown in FIG. 21, the laminated iron core 15 is formed by laminating a predetermined number of steel sheets made of an electromagnetic steel sheet or a silicon steel sheet having a thickness dimension of about 0.1 mm to 3.0 mm according to a desired axial length dimension. A cylindrical central portion 15b in which an insertion hole 15a of the shaft 12 is formed, a teeth portion 15c protruding from the central portion 15b of the iron core to the outer peripheral side in the radial direction D, and a circumferential direction from the teeth portion 15c. It has a fan-shaped outer peripheral portion 15d of an iron core in a plan view extending along R.

Further, the resin insulating portion 16 is formed by injection molding using, for example, a thermoplastic resin such as PPS, LCP, PBT, POM, PA, PET, SPS, an epoxy resin, or a thermosetting resin such as BMC to form a laminated iron core 15. It is integrally molded.

Here, the resin insulating portion 16 is formed so as to cover the entire surface of the laminated iron core 15. That is, it is formed so as to cover the entire surface of the core central portion 15b, the teeth portion 15c, and the outer peripheral portion 15d of the laminated iron core 15.

In particular, the resin insulating portion 16 that covers the surface of the teeth portion 15c around which the coil of the laminated iron core 15 is wound is the end face winding portion 16c formed by covering both end faces of the teeth portion 15c in the axial direction X and the teeth. It is composed of a side winding portion 16d formed by covering a side surface portion extending along the axial direction X facing the circumferential direction R of the portion 15c. The side winding portion 16d avoids interference between the coil wound around the own teeth portion and the coil of another teeth portion adjacent to the circumferential direction R, and improves the coil space factor of the coil wound around the own teeth portion. Therefore, it is desired to form the thickness thin and long in the axial direction X. The end face winding portion 16c is configured so as not to impair the minimum bending radius of the conductor forming the coil 14, and the thickness thereof is as shown in FIG. 22 (maximum thickness T11 of the end face winding portion 16c). > (Maximum thickness W12 of the side winding portion 16d). The resin insulating portion 16 is provided with a resin injection port mark at a portion formed on the end face of the laminated iron core 15 in the axial direction X.

In this way, the resin insulating portion 16 (that is, the end face winding portion 16c and the side winding portion 16d) is formed by covering at least the surface portion of the teeth portion 15c around which the coil is wound of the laminated iron core 15. The insulated iron core 13 and the coil are electrically insulated so that the required characteristics of the rotary electric machine can be exhibited.

Further, in the case of the second embodiment (see FIG. 22), the thickness T11 of the end surface winding portion 16c is uniform over the entire surface, but the thickness of the side winding portion 16d is the thickness of both end faces along the axial direction X. The bulge portion is formed so that the thickness W12 in the circumferential direction R becomes the wall thickness on the central side of the thickness W11. Therefore, the thickness T11 described above is the maximum thickness T11 of the end face winding portion 16c, and the thickness W12 is the maximum thickness W12 of the side winding portion 16d. That is, the bulging portion 16d, which is the side winding portion in this case, is formed in a semi-spindle shape so that the thickness gradually decreases toward both end faces with the center of the axial direction X as the apex. Moreover, in this case, as shown in FIG. 22, the bulging portion 16d is the coil 14 with reference to the surface of the teeth portion 15c facing the circumferential direction R when the coil 14 is wound on the bulging portion 16d. It is formed so as to bulge in the circumferential direction R within a range smaller than the winding swelling gap G2 generated between the two.

When a conductor is wound around the end face winding portion 16c and the side winding portion 16d covering the surface portion of the tooth portion 15c of the laminated iron core 15 to form a coil 14, the conductor cannot be wound in a straight line due to the elasticity of the conductor. The end face winding portion 16c and the side winding portion 16d are arranged in an arc shape. Therefore, as shown in FIG. 22, a winding swelling gap G2 is generated between the tooth portion 15c and the coil 14 with reference to the surface facing the circumferential direction R. In the second embodiment, as described above. Since the bulging portion 16d as the side winding portion is formed so as to bulge in the circumferential direction R within a range smaller than the winding bulging gap G2 of the coil 14, it is the same as in the case of the first embodiment. The thickness of the bulging portion 16d in the circumferential direction R can be made as large as possible to ensure insulation, and there is no need to reduce the number of turns of the coil 14 to be wound. That is, even if the bulging portion 16d is formed, the coil space factor of the coil 14 is not lowered. Therefore, the insulation function can be improved without significantly deteriorating the performance of the rotary electric machine, and an efficient rotary electric machine can be obtained.

On the other hand, in the case of the comparative technique 3 shown in FIG. 23, among the resin insulating portions 16 covering the surface portion of the teeth portion 15c of the laminated iron core 15, particularly the side winding portion 616d is directed toward the circumferential direction R. It is not formed to bulge, and the thickness along the axial direction is formed as a uniform flat portion.

As described above, in the case of the comparative technique 3 shown in FIG. 23, since the thickness of the side winding portion 616d in the circumferential direction R is thin and uniform along the axial direction X, the coil 14 and the laminated iron core 15 are electrically insulated. Function is reduced. As a countermeasure, if the thickness of the side winding portion 616d is set to be uniformly large, the deterioration of the insulating function can be prevented, but the number of turns of the coil 14 to be wound is reduced, and the performance of the rotary electric machine is deteriorated. In the case of the present embodiment, such inconvenience due to the comparison technique 3 does not occur.

Next, the manufacturing process of the rotor of the rotary electric machine shown in FIGS. 17 to 20 will be described.
FIG. 24 is a flowchart showing the process of the rotor manufacturing method according to the second embodiment of the present application, and FIGS. 25A to 25F show a procedure in the case of injection molding a resin insulating portion for each laminated iron core using a molding die. FIG. 26 is a partially enlarged cross-sectional view when the insulating resin is injected into the laminated iron core using a molding die, and FIG. 27 is an insulating resin when the insulating resin is injected into the laminated iron core using a molding die. It is explanatory drawing which shows the flow state of.

As shown in the flowchart of FIG. 24, first, the laminated iron core 15 shown in FIG. 25A (FIG. 21) is formed by press-molding and laminating the steel plates. Then, the laminated iron core 15 shown in FIG. 25A is positioned and fixed in the molding die 17 (FIGS. 25B and 25C). After that, an insulating resin is injection-molded in the molding die 17 to form the insulated iron core 13 shown in FIGS. 17 to 20 in which the resin insulating portion 16 is integrally formed with the laminated iron core 15 (FIG. 25D). After the injection molding is completed, the insulating iron core 13 is separated from the molding die 17 (FIG. 25E), and the unnecessary resin portion is removed (FIG. 25F). At this time, a resin injection port mark remains. Next, the rotor is formed by inserting the shaft 12 into the insulated iron core 13 and winding a conductor around the insulated iron core 13 to form the coil 14. At that time, a method of injecting an insulating resin after inserting the shaft 12 into the laminated iron core 15 to integrally mold the resin insulating portion 16 and a method of injecting an insulating resin into the laminated iron core 15 to integrally integrate the resin insulating portion 16. There is a method of inserting the shaft 12 after molding, but any method may be used.

Here, a method for injection molding the resin insulating portion 16 with respect to the laminated iron core 15 will be described in more detail.

As shown in FIGS. 25B and 25C, first, the laminated iron core 15 shown in FIG. 25A (FIG. 21) is placed in the molding die 17, positioned, and fixed. The molding die 17 includes a mold inner wall 17a that seals the core central portion 15b, the teeth portion 15c, and the iron core outer peripheral portion 15d of the laminated iron core 15, and resin injection ports provided on the upper and lower flat end faces in the axial direction X. It has 17b and.

In particular, in the molding die 17 in this case, as shown in FIGS. 25B to 25E and 26, a side winding portion 16d is formed on the side surface in the axial direction X for the purpose of improving the coil space factor. It has a cavity for forming the end face winding portion 16c on the end face in the axial direction in order to secure the minimum bending radius of the conductor forming the coil 14. A recess 17d for forming a bulging portion 16d having a wall thickness in the circumferential direction is formed in advance on the central side of both end faces along the axial direction X of the laminated iron core 15. Further, as shown in FIG. 27, the resin injection port 17b is arbitrarily provided at the position of both end faces of the central portion 15b of the laminated iron core 15 or the outer peripheral portion 15d of the iron core in the axial direction X, and is used for insulation from the resin injection port 17b. The resin is injected.

The arrows in FIG. 27 indicate, for example, the flow direction when the insulating resin is injected from the upper and lower resin injection ports 17b. The injected insulating resin flows through the cavity, which is the space between the inner wall 17a of the mold and the laminated iron core 15, and is cured after filling, so that the resin insulating portion 16 integrated to cover the laminated iron core 15 is formed. It is formed. Therefore, in the case of FIG. 27, since the insulating resin is injected from each resin injection port 17b, the central portion in the axial direction X that flows into the cavity along the axial direction X of the laminated iron core 15 becomes the resin flow end portion E2. Become.

In the process of the insulating resin flowing in the cavity between the laminated iron core 15 and the inner wall 17a of the mold, it receives a pressure loss due to flow resistance. The magnitude of the pressure loss ΔP is shown by the above-mentioned (Equation 1), and the smaller the wall thickness dimension M corresponding to the flow path depth in the flow path cross section of the insulating resin, the larger the resistance, and the resin flow end portion. The pressure tends to be insufficient.

However, in the case of the second embodiment, as in the case of the first embodiment, the molding die 17 has the resin insulating portion 16 as shown in FIGS. 25B to 25E and 26 (see FIG. 22). Along the axial direction X, which is the resin flow end portion E2 of the insulating resin, the center side (resin) from both end surfaces (corresponding to the portion of the side winding portion 16d in FIG. 22 after the resin insulating portion 16 is formed and the thickness W11). Since the recess 17d for forming the bulging portion, which becomes thicker in the circumferential direction, is formed in advance in the portion of the side winding portion 16d of FIG. 22 after the insulating portion 16 is formed, which corresponds to the thickness W12), the resin. Since the flow path depth M of the cavity gradually increases from the injection port 17b to the resin flow end portion E2, the decrease in the pressure loss ΔP is suppressed. As a result, poor filling at the resin flow end portion E2 can be prevented, and the insulating function can be improved.

Then, even if the resin injection port 17b is arranged in the vicinity of the side winding portion 6d having a thin wall thickness W11 such as both end faces along the axial direction X, the above-mentioned pressure loss (Equation 1) shown above is obtained. ), The resin easily flows to the end face winding portion 16c (including the top of the iron core central portion 15b and the iron core outer peripheral portion 15d), and the side winding portion 16d becomes the resin flow end portion E2 of the insulating resin.

On the other hand, in the case of the comparative technique 4 shown in FIG. 28, the recess 17d for forming the bulging portion, which becomes thicker in the circumferential direction as in the second embodiment of the present application, is not formed. Since the mold inner wall 617a is formed so that the flow path depth M in the cavity becomes thin and uniform along the axial direction X, the pressure loss ΔP increases from the resin injection port 17b to the resin flow end portion, and insulation is provided. The flow of the resin for use stops, and poor resin filling and deterioration of the insulating function are likely to occur.

As described above, in the second embodiment, the resin insulating portion 16 integrated with the laminated iron core 15 has a circumferential direction R on the central side of the thickness W11 of both end surfaces along the axial direction of the laminated iron core 15. Since the bulging portion 16d having a thickness W12 toward the wall is formed, the pressure loss ΔP due to the increase in the flow resistance when the insulating resin is injection-molded using the molding die 17 is increased. It can be reduced, and the filling property of the insulating resin and the insulating performance can be improved.

Moreover, the center of the wound coil 14 is wound and expanded due to elastic deformation, but the bulging portion 16d of the resin insulating portion 16 has a thickness in the circumferential direction R on the center side of the thickness W11 of both end surfaces thereof. Since the W12 is formed to be thick, the gap between the coil 14 and the bulging portion 16d becomes small, and the number of turns of the coil 14 to be wound is not reduced, and the coil 14 is occupied. The decrease in the rate is suppressed. Therefore, the insulation function can be improved without deteriorating the performance of the rotary electric machine, and it is possible to provide an insulating structure of the rotary electric machine having a small size, high efficiency, and sufficient insulation performance.

Further, since it is not necessary to select an expensive insulating resin having good fluidity and it is not necessary to locally heat the molding die 7 in order to improve the fluidity of the insulating resin, the material cost and equipment By controlling the cost, it is possible to provide an inexpensive rotary electric machine.

By the way, as shown in FIGS. 25B to 25E and 26, when resin injection ports 17b are provided at both ends of the molding die 17 in the axial direction X, the resin flow end portion E2 is in the axial direction of the side winding portion 16d. Although it is formed in the center along X, the flow of the insulating resin and the position of the resin flow end portion E2 change depending on the shape of the resin insulating portion 16.

Therefore, the bulging portion 16d of the resin insulating portion 16 is formed in a semi-spindle shape so as to have a wall thickness of W12 gradually in the circumferential direction R from the thickness W11 of both end surfaces thereof along the axial direction X. For example, as shown in FIG. 29, a cross section having a thickness W12 in the circumferential direction R on the central side of the thickness W11 of both end faces thereof is formed in a trapezoidal shape. As shown in FIG. 30 or the bulging portion 16d, a cross section having a thickness W12 in the circumferential direction R is formed in a protruding shape on the central side of the thickness W11 of both end surfaces thereof along the axial direction X. By changing the shape of the recess 17d of the molding die 17 so that the formed bulging portion 16d is formed, the increase in flow resistance when injection molding the insulating resin using the molding die 17 is locally increased. It is possible to improve the insulation function by suppressing the target.

Further, when the resin injection port 17b of the molding die 17 is provided at only one place on one side in the axial direction X, for example, the resin flow end portion E2 is at the center of the side winding portion (bulging portion) 16d in the axial direction X. It may shift from the position. Also in that case, the position of the bulging portion 16d having a trapezoidal cross section shown in FIG. 29 or the bulging portion 16d having a protruding cross section shown in FIG. 30 is appropriately positioned from the central position in the axial direction X. By forming them in a staggered manner, the same effect of improving the insulating function can be obtained.

The insulating structure of the rotary electric machine according to the second embodiment is of various rotary electric machines for servo motors, fuel injection valve opening / closing timing control units, air conditioning fan motors, in-vehicle fuel pump units, hoisting machines, and the like. It can be applied to rotors.

In the first and second embodiments, the lengths of the laminated iron cores 5 and 15 around which the coils are wound in the circumferential direction R are formed to have the same length at any position in the axial direction X. However, the present invention is not limited to this, and for example, as shown in FIGS. 31 to 33, the length of the circumferential direction R of the laminated iron cores 5 and 15 at the portion where the coil is wound is set in the axial direction. It is also conceivable to form a portion where the length H2 in the circumferential direction R is shorter than the length H1 in the circumferential direction R on both end sides of the X on the central side of the axial direction X. When formed in this way, the portions corresponding to the resin flow end portions E1 and E2 in the integral molding are dented positions in the circumferential direction R of the laminated iron cores 5 and 15, so that the viscosity of the insulating resin increases. The filling properties of the flow end portions E1 and E2 are improved, and the insulation performance of the resin insulating portion can be improved.

According to the method for manufacturing the insulating structure of the rotating electric machine and the insulating structure of the rotating electric machine according to the second embodiment configured as described above, it goes without saying that the same effect as that of the first embodiment is obtained. Since the portion of the laminated iron core around which the coil is wound has a portion formed in which the length in the circumferential direction is shorter on the central side in the axial direction than the length in the circumferential direction on both end sides in the axial direction.
The filling property of the insulating resin can be further improved.

Embodiment 3.
FIG. 34 is a perspective view showing six teeth, which is a half circumference when applied to a stator as an insulating structure of a rotary electric machine according to a third embodiment of the present application, and FIG. 35 constitutes the stator of FIG. 34. A perspective view showing one of the split stators, FIG. 36 is a perspective view showing an insulating split iron core constituting the split stator of FIG. 35. Further, FIG. 37 is a front view of the insulated split iron core of FIG. 36 as viewed from the circumferential direction, and FIG. 38 is a perspective view of the case where the insulated split iron core of FIG. 37 is cut along the CC line. Further, FIG. 39 is a perspective view of the laminated iron core constituting the insulated divided iron core of FIG. 36, and FIG. 40 is a cross-sectional view showing a state in which a coil is wound around the insulated divided iron core in the third embodiment. Here, it is assumed that the axial direction of the stator or the split stator is indicated by reference numeral X, the radial direction is indicated by reference numeral D, and the circumferential direction is indicated by reference numeral R.

The stator 101 of the third embodiment is configured by connecting the dividing stators 102 for 12 teeth in an annular shape along the circumferential direction R of the rotary electric machine. In this case, each of the split stators 102 is composed of an insulating split iron core 103 and a coil 104. The coil 104 is formed by winding a conductor such as a copper electric wire or an aluminum electric wire around an insulating divided iron core 103 a desired number of times. Although the number of teeth is set to 12 here, the number is not limited to this, and it can be arbitrarily designed according to the performance and structure of the rotary electric machine.

As shown in FIGS. 36 to 38, the insulating divided iron core 103 includes a laminated iron core 105 and a resin insulating portion 106.
Here, as shown in FIG. 39, the laminated iron core 105 is formed by laminating a predetermined number of steel sheets made of an electromagnetic steel sheet or a silicon steel sheet having a thickness dimension of about 0.1 mm to 3.0 mm in accordance with a desired axial length dimension L100. It is composed of. The laminated iron core 5 has a back yoke portion 105a that extends in a fan shape in a plan view along the circumferential direction R, a teeth portion 105b that protrudes from the back yoke portion 105a toward the center of the stator 101, and a teeth portion 105b in the circumferential direction. It has a protrusion 105c extending along R.

Further, the resin insulating portion 106 is injection-molded using, for example, a thermoplastic resin such as PPS, LCP, PBT, POM, PET, PA, SPS, an epoxy resin, or a thermosetting resin such as BMC, SMC. It is formed.

The resin insulating portion 106 is assembled from two directions above and below the axial direction X with respect to the laminated iron core 105, so that the teeth portion 105b of the laminated iron core 105, both end faces of the back yoke portion 105a in the axial direction X, and the protruding portions. It is formed so as to cover both end faces of the axial direction X of 105c. Specifically, the resin insulating portions covering both end faces of the back yoke portion 105a and the protruding portion 105c in the axial direction X are flanged portions 106a protruding from the axial end faces of the laminated iron core 5 by a predetermined length L101, respectively. It is formed as 106b. The flange portions 106a and 106b are set so as to reliably maintain the insulated state of the coil 104 by projecting further in the axial direction X than the winding position of the coil 104.

Further, the resin insulating portion covering the surface of the teeth portion 105b around which the coil 104 is wound covers the end face winding portions 106c formed by covering both end faces of the teeth portion 105b in the axial direction X and the circumference of the teeth portion 105b. It is composed of a side winding portion 106d formed so as to cover a side surface portion extending along the axial direction X facing the direction R. The side winding portion 106d avoids interference between the coil wound around the own teeth portion and the coil of another teeth portion adjacent to the circumferential direction R, and improves the coil space factor of the coil wound around the own teeth portion. Therefore, it is desired to form the thickness thin and long in the axial direction X. The end face winding portion 106c is configured so as not to impair the minimum bending radius of the conductor forming the coil 104, and its thickness is as shown in FIG. 40 (maximum thickness T111 of the end face winding portion 106c). > (Maximum thickness W102 of the side winding portion 106d). The resin insulating portion 106 is provided with a resin injection port mark 106e at a portion formed on the end surface of the laminated iron core 105 in the axial direction X.

In this way, the resin insulating portion 106 (that is, the end surface winding portion 106c and the side winding portion 106d) is formed by covering the surface portion of the teeth portion 105b around which at least the coil 104 of the laminated iron core 105 is wound. The insulating split iron core 103 and the coil 104 are electrically insulated so that the required characteristics of the rotary electric machine can be exhibited.

Further, in the case of the third embodiment (see FIG. 40), the thickness T111 of the end face winding portion 106c is uniform over the entire surface, but the thickness of the side winding portion 106d is the thickness of both end faces along the axial direction X. It is formed as a bulging portion so that the thickness W102 in the circumferential direction R becomes thicker on the central side than the thickness W101. Therefore, the thickness T111 described above is the maximum thickness T111 of the end face winding portion 106c, and the thickness W102 is the maximum thickness W102 of the side winding portion 106d. That is, the bulging portion 106d, which is the side winding portion in this case, is formed in a semi-spindle shape so that the thickness gradually decreases toward both end faces with the center of the axial direction X as the apex. Moreover, in this case, as shown in FIG. 40, the bulging portion 106d is the coil 104 with reference to the surface of the teeth portion 105b facing the circumferential direction R when the coil 104 is wound on the bulging portion 106d. It is formed so as to bulge in the circumferential direction R within a range smaller than the winding swelling gap G3 generated between the two.

When forming a coil 104 by winding conductors such as copper electric wires and aluminum electric wires, which are elastic bodies, around the end face winding portion 106c and the side winding portion 106d covering the surface portion of the tooth portion 105b of the laminated iron core 105. Due to the elasticity of the conductor, it cannot be wound in a straight line, and is bulged and arranged in an arc shape at the end face winding portion 106c and the side winding portion 106d. Therefore, as shown in FIG. 40, a winding swelling gap G3 is generated between the tooth portion 105b and the coil 104 with reference to the surface facing the circumferential direction R. In the third embodiment, as described above. Since the bulging portion 106d as the side winding portion is formed so as to bulge in the circumferential direction R within a range smaller than the winding bulging gap G3, the thickness of the bulging portion 106d in the circumferential direction R Insulation can be ensured by making the coil 104 as large as possible, and there is no need to reduce the number of turns of the coil 104 to be wound. That is, even if the bulging portion 106d is formed, the coil space factor of the coil 104 is not lowered. Therefore, the insulation function can be improved without significantly deteriorating the performance of the rotary electric machine, and an efficient rotary electric machine can be obtained.

On the other hand, in the case of the comparative technique 5 shown in FIG. 41, the resin insulating portions 106 covering the surface portion of the teeth portion 105b of the laminated iron core 105 are formed at both ends of the laminated iron core 105 in the axial direction X. Since the end face winding portion 606c is formed so as to bulge in the axial direction X, the difference is that the gap G101 between the coil 104 and the end face winding portion 606c is narrowed.

As described above, in the case of the comparative technique 5 shown in FIG. 41, when the coil is wound by the conductor, the protrusion, which is the resin injection port mark 606e installed in the end face winding portion 606c, comes into contact with the coil 104 and electrically. The function of insulating is reduced. In the present application, as shown in FIG. 40, the end face winding portion 106c has a flat portion and has a gap G10 between the coil 104 and the end face winding portion 106c, so that the resin injection port mark 106e and the coil 104 Since they do not come into contact with each other, there is no deterioration in insulation performance that may occur in Comparative Technique 5.

Next, the manufacturing process of the stator 101 of the rotary electric machine shown in FIG. 34 will be described.
42 is a flowchart showing the process of the stator manufacturing method according to the third embodiment of the present application, FIGS. 43A to 43C are explanatory views showing an assembly procedure of the stator, and FIGS. 44A to 44E are resins using a molding die. Explanatory drawing showing a procedure in the case of injection molding of an insulating part, FIG. 45 is a partially enlarged cross-sectional view when injecting an insulating resin using a molding die, and FIG. It is explanatory drawing which shows the flow state of the insulating resin in the case of this.

As shown in the flowchart of FIG. 42, first, a plurality of laminated iron cores 105 are formed by press-molding and laminating steel plates. Next, the molding die 107 is moved in the vertical direction in the axial direction X (FIG. 44A) and installed at a predetermined position (FIG. 44B). Next, the insulating resin is injection-molded in the molding die 107 (FIG. 44C). After the injection molding is completed, the molding die 107 is separated in the vertical direction in the axial direction X, and the resin insulating portion 106 is taken out (FIG. 44D). Next, the unnecessary resin portion is removed (FIG. 44E). At this time, the resin injection port mark 106e remains.

Next, the resin insulating portion 106 is assembled to the laminated iron core 105 from two directions above and below the axial direction X (FIG. 43A), and the insulating divided iron core 103 is formed (FIGS. 43B and 36). Next, a conductor is wound around the insulating split iron core 103 to form a coil 104 to form a split stator 102 (FIGS. 43C and 35). Then, the stator 101 is configured by connecting and arranging a predetermined number of the dividing stators 102 in an annular shape along the circumferential direction R.

Here, a method for injection molding the resin insulating portion 106 for each laminated iron core 105 will be described in more detail.

As shown in FIGS. 44A and 44B, the cavity for forming the resin insulating portion 106 is formed by sealing the molding die 107. The molding die 107 has a mold inner wall 107a for forming the resin insulating portion 106, and a resin injection port 107b provided on a flat surface which is an end surface in the axial direction X.

In particular, the molding die 107 applied to the third embodiment is side-wound on the side surface in the axial direction X for the purpose of improving the coil space factor, as shown in FIGS. 44B to 44E and 45. It has a cavity for forming the mounting portion 106d and a cavity for forming the end face winding portion 106c on the end face in the axial direction in order to secure the minimum bending radius of the conductor forming the coil 104. Corresponding to the central portion of the laminated iron core 5 assembled to the molding die 107 along the axial direction X, the wall thickness is increased in the circumferential direction on the central side of both end faces along the axial direction X of the laminated iron core 5. A recess 107d for forming the bulging portion 106d is formed in advance. Further, as shown in FIG. 46, the resin injection port 107b is arbitrarily provided at a position where, for example, the flange portion 106b or the end face winding portion 106c of the resin insulating portion 106 is formed, and the insulating resin can be removed from the resin injection port 107b. Infused.

The arrow in FIG. 46 indicates, for example, the flow direction when the insulating resin is injected from the upper resin injection port 107b. The injected insulating resin flows through the cavity which is the space of the inner wall 107a of the molding die 107, and is cured after filling to form the upper side of the resin insulating portion 106. Therefore, in the case of FIG. 46, since the insulating resin is injected from the resin injection port 107b, the portion corresponding to the central portion in the axial direction X that flows into the cavity along the axial direction X becomes the resin flow end portion E3. .. As a matter of course, the lower side of the resin insulating portion 106 is also formed in the same manner as the upper side.

In the process of the insulating resin flowing through the cavity of the mold inner wall 107a of the molding mold 107, it receives a pressure loss due to the flow resistance. Here, as shown in FIG. 13, the flow path depth in the cavity is M, the flow path width is N, the flow path length is L, the proportional multiplier is K, the flow rate is Q, and the starting end for injecting the insulating resin. The pressure loss ΔP (= Pin-Pout) is represented by the above (Equation 1), where Pin is the pressure of and Pout is the end pressure.

As can be seen from the above (Equation 1), the smaller the flow path depth M of the cavity in the flow path cross section of the insulating resin, the larger the flow resistance and the larger the pressure loss ΔP. That is, when the insulating resin flows through the cavity, if the flow path depth M in the cavity is small, the pressure loss ΔP from the resin injection port 7b shown in FIG. 46 to the resin flow end portion E3 becomes large. The pressure tends to be insufficient at the resin flow end portion E1. When the pressure is insufficient at the resin flow end portion E3, the flow of the insulating resin is stopped, resulting in poor filling of the insulating resin and deterioration of the insulating function. This is because the thickness of the resin insulating portion 106 (flow) is seen from the result after the insulating resin is injected into the sealed cavity of the mold inner wall 107a of the molding mold 107 and the resin insulating portion 106 is formed. The thinner the path depth (corresponding to the path depth M), the more likely it is that poor filling of the resin flow end portion of the insulating resin and deterioration of the insulating function occur.

In the case of the third embodiment, as shown in FIGS. 44A to 44E and 45 (see FIG. 40), the molding die 107 has a resin flow end portion E3 of the insulating resin of the resin insulating portion 106. Along the axial direction X, the side surface (corresponding to the portion of the thickness W101 of the side winding portion 116d in FIG. 40 after the resin insulating portion 116 is formed) is closer to the center side (the side winding in FIG. 40 after the resin insulating portion 116 is formed). A recess 107d for forming a bulging portion, which becomes thicker in the circumferential direction R, is formed in advance in the portion 116d (corresponding to the portion of the thickness W102). Therefore, since the flow path depth M of the cavity gradually increases from the resin injection port 107b to the resin flow end portion E3, the decrease in the pressure loss ΔP is suppressed. As a result, poor filling at the resin flow end portion E3 can be prevented, and the insulating function can be improved.

Then, even if the resin injection port 107b is arranged in the vicinity of the side winding portion 106d having a thin wall thickness W101 such as both end faces along the axial direction X, the pressure loss (Equation 1) shown above causes the pressure loss. , The insulating resin easily flows to the end face winding portion 106c, the flange portion 106a on the back yoke portion 105a, and the flange portion 106b on the protruding portion 105c, and the side winding portion 106d becomes the resin flow end portion E3 of the insulating resin. Become.

On the other hand, in the case of the comparative technique 5 shown in FIG. 47, the resin insulating portions are assembled from two vertical directions as in the third embodiment of the present application, but the two resin insulating portions are formed. Is separated in the axial direction X and does not have a structure to be fitted. Therefore, the creepage distance cannot be extended to improve the insulation performance.

As described above, in the third embodiment, the resin insulating portion 106 has the thickness W101 of both end surfaces along the axial direction X of the laminated iron core 105 at the portion corresponding to the central portion of the laminated iron core 105 to be assembled. Since the bulging portion 106d having a wall thickness W102 in the circumferential direction R is formed on the central side of the molding die 107, the flow resistance when the insulating resin is injection-molded using the molding die 107 is formed. The pressure loss ΔP due to the increase can be reduced, and the filling property of the insulating resin and the insulating performance can be improved.

Moreover, the center of the coil 104 to be wound swells due to elastic deformation, but the bulging portion 106d of the resin insulating portion 106 has a thickness in the circumferential direction R on the center side of the thickness W101 of both end faces thereof. Since the W102 is formed to be thick, the gap between the coil 104 and the bulging portion 106d becomes small, and the number of turns of the coil 104 to be wound is not reduced, and the coil 104 is occupied. The decrease in the rate is suppressed. Therefore, the insulation function can be improved without deteriorating the performance of the rotary electric machine, and it is possible to provide an insulating structure of the rotary electric machine having a small size, high efficiency, and sufficient insulation performance.

Further, since it is not necessary to select an expensive insulating resin having good fluidity and it is not necessary to locally heat the molding die 107 in order to improve the fluidity of the insulating resin, the material cost and equipment By controlling the cost, it is possible to provide an inexpensive rotary electric machine.

By the way, as shown in FIGS. 44A to 44E and 45, when the resin injection port 107b is provided on the end surface of the molding die 107 in the axial direction X, the resin flow end portion E3 becomes the axial direction X of the side winding portion 106d. Although it is formed in the central portion along the above, the flow of the insulating resin and the position of the resin flow end portion E3 change depending on the shape of the resin insulating portion 106.

Therefore, the bulging portion 106d of the resin insulating portion 106 is formed in a semi-spindle shape so as to have a wall thickness of the thickness W102 in the circumferential direction R gradually from the thickness W101 of both end surfaces thereof along the axial direction X. For example, as shown in FIG. 48, a cross section having a thickness W102 in the circumferential direction R on the center side of the thickness W101 of both end faces thereof is formed in a trapezoidal shape. As shown in FIG. 49 or the bulging portion 106d, a cross section having a thickness W102 in the circumferential direction R is formed in a protruding shape on the central side of the thickness W101 of both end surfaces thereof along the axial direction X. By changing the shape of the recess 107d of the molding die 107 so that the formed bulging portion 106d is formed, the increase in flow resistance when injection molding the insulating resin using the molding die 107 is locally increased. It is possible to improve the insulation function by suppressing the target.

For example, as a comparative technique, it is conceivable that the resin insulating portion around which the coil is wound has protrusions on both end faces in the axial direction, but the difference is that the protrusions are arranged on the end faces in the axial direction, as in the present application. The difference is that the effect of improving the insulation performance on both sides in the axial direction cannot be obtained. Therefore, the difference is that the insulation performance can be improved without lowering the space factor of the coil as in the present application, and there is an effect that a small rotary electric machine can be obtained with the same performance. Furthermore, as in the present application, by reducing the air layer between the coil and the insulating part, the efficiency of transmitting heat generated by the coil to the iron core is improved, so that the same size and higher efficiency and heat dissipation parts are reduced compared to the conventional structure. It differs in that it has the effect of obtaining a rotating electric machine.

The insulating structure of the rotary electric machine according to the third embodiment is of various rotary electric machines for servomotors, fuel injection valve opening / closing timing control units, air conditioning fan motors, in-vehicle fuel pump units, hoisting machines, and the like. It can be applied to stators.

In the third embodiment, an example of assembling the resin insulating portion 106 with respect to the laminated iron core 105 from two directions above and below the axial direction X has been shown, but the present invention is not limited to this, and the resin insulating portion 106 is not limited to this, and is above and below the axial direction X. It is possible to assemble from a plurality of places, and even in that case, the same effect as that of the third embodiment can be obtained.

Further, in the third embodiment, the resin insulating portion 106 is illustrated with a resin injection port mark 106e at a portion formed on the end face of the laminated iron core 105 in the axial direction X, but in the drawing, it is shown. Although it is shown large to clarify the difference from the comparative technique, the resin injection port mark is small, so that the illustration is omitted in the first and second embodiments.

According to the method for manufacturing the insulating structure of the rotary electric machine and the insulating structure of the rotary electric machine according to the third embodiment configured as described above, the same effect as that of each of the above-described embodiments can be obtained.
Insulation of a rotary electric machine is provided with a laminated iron core in which a plurality of steel plates are laminated, and a resin insulating portion covering at least the surface portion of a portion where a coil is wound is assembled from two or more axial directions on the laminated iron core. In the structure
In the resin insulating portion, the maximum thickness of the portion formed on the axial end face of the laminated iron core is thicker than the maximum thickness of the portion formed along the axial direction of the laminated iron core, and the laminated iron core is formed. Has a resin injection port mark on the end face in the axial direction of
In the resin insulating portion, the thickness of the portion where the end face in the axial direction of the laminated iron core is formed is uniformly formed.
Since the resin insulating portion includes a bulging portion formed thickly in the circumferential direction on the central side of both end faces along the axial direction of the laminated iron core, the resin insulating portion includes a bulging portion.
Further, a rotary electric machine is provided with a laminated iron core in which a plurality of steel plates are laminated, and a resin insulating portion covering at least a surface portion of a portion where a coil is wound is assembled from two or more axial directions on the laminated iron core. It is a manufacturing method of the insulating structure of
A molding mold for injection molding in which the resin insulating portion is divided into two or more directions in the axial direction is applied, and the inner wall of the mold of the molding mold is on the center side of both end faces along the axial direction of the laminated iron core. In the above, a concave portion for forming a bulging portion that becomes thicker in the circumferential direction was formed in advance, and an insulating resin was injected from the resin injection port of the molding mold to be divided into two or more directions in the axial direction. After molding the resin insulating portion and taking out the resin insulating portion divided into two or more directions in the axial direction from the molding mold, the resin insulating portion divided into two or more axial directions in the laminated iron core. Is assembled from two or more axial directions, so
The central portion of the wound coil in the axial direction swells due to elastic deformation, but the bulging portion is formed so as to become thicker in the circumferential direction on the central side than both end faces in the axial direction. Therefore, the insulation performance can be improved without lowering the coil space factor of the coil, and an insulating structure of a small rotary electric machine, and eventually a rotary electric machine can be obtained with the same performance. Further, by reducing the air layer between the coil and the resin insulating portion, the efficiency of transmitting the heat generated by the coil to the laminated iron core is improved, so that the conventional structure does not cause an extra cost increase or performance deterioration. It is possible to obtain an insulating structure of a rotating electric machine having the same size, high efficiency, and reduced heat dissipation parts, and by extension, a rotating electric machine.
Further, the inner wall of the die of the molding die is formed by preliminarily forming a recess for forming a bulging portion which becomes thicker in the circumferential direction on the central side than both end faces along the axial direction of the laminated iron core. After arranging the laminated iron core inside the mold, the insulating resin is injected from the resin injection port of the molding mold.
It is possible to reduce the pressure loss caused by the increase in the flow resistance when filling the insulating resin. Therefore, since the filling property of the insulating resin is improved, it is not necessary to select an expensive insulating resin having good fluidity, and local heating of the molding die is performed in order to improve the fluidity of the insulating resin. Since there is no need to do so, material costs and equipment costs can be suppressed, and an inexpensive rotating electric machine insulating structure and thus a rotating electric machine can be provided.

Although various exemplary embodiments have been described in the present application, the various features, embodiments, and functions described in one or more embodiments may be applied to a particular embodiment. It is not limited and can be applied to embodiments alone or in various combinations.

Therefore, innumerable variations not illustrated are envisioned within the scope of the techniques disclosed in the present application. For example, it includes the case of transforming, adding, or omitting at least one component, and further, the case of extracting at least one component and combining it with the component of another embodiment. ..

1 Stator, 2 Split stator, 3 Insulated split iron core, 4 Coil, 5 Laminated iron core, 5a Back yoke part, 5b Teeth part, 5c Protruding part, 6 Resin insulation part, 6a, 6b Die part, 6c End face winding part , 6d side winding part, 7 molding die, 7a mold inner wall, 7b resin injection port, 7d recess, G1 winding bulge gap, 11 rotor, 12 shaft, 13 insulated iron core, 14 coil, 15 laminated iron core, 15a insertion Hole, 15b Central part of iron core, 15c Teeth part, 15d Outer part of iron core, 16 Resin insulation part, 16c End face winding part, 16d Side winding part, 17 Molding mold, 17a Mold inner wall, 17b Resin injection port, 17d Recess , G2 winding swelling gap, 101 stator, 102 split stator, 103 insulated split iron core, 104 coil, 105 laminated iron core, 105a back yoke part, 105b teeth part, 105c protruding part, 106 resin insulating part, 106a, 106b flange part , 106c end face winding part, 106d side winding part, 106e resin injection port mark, 107 molding mold, 107a mold inner wall, 107b resin injection port, 107d recess, G3 winding bulge gap, 606c end face winding part, 606e resin Injection mark, 606d side winding part, 607a mold inner wall, 616d side winding part, 617a mold inner wall.

The insulating structure of a rotary electric machine disclosed in the present application is
A laminated iron core formed by laminating a plurality of steel plates is provided, and a resin insulating portion is integrally formed on the laminated iron core so as to cover at least a surface portion of a portion where a coil is wound, and the coil is formed on the resin insulating portion. In the insulating structure of the rotating electric machine that is wound with
The resin insulating portion includes a bulging portion formed thickly in the circumferential direction on the central side of both end faces along the axial direction of the laminated iron core .
In the resin insulating portion, the maximum thickness of the portion formed on the axial end face of the laminated iron core is thicker than the maximum thickness of the portion formed along the axial direction of the laminated iron core, and the laminated iron core is formed. A resin injection port mark is provided at a portion formed on the end face in the axial direction of the above.
Further, the insulating structure of the rotary electric machine disclosed in the present application is:
Provided with a laminated core in which a plurality of steel plates are laminated, the resin insulating portion covering the surface portion places the the laminated core is to be at least the coil is wound is assembled from two or more directions in the axial direction, the resin insulation the coil on the part is in the insulating structure of the rotary electric machine that has been wound,
In the resin insulating portion, the maximum thickness of the portion formed on the axial end face of the laminated iron core is thicker than the maximum thickness of the portion formed along the axial direction of the laminated iron core, and the laminated iron core is formed. Has a resin injection port mark on the end face in the axial direction of
In the resin insulating portion, the thickness of the portion where the end face in the axial direction of the laminated iron core is formed is uniformly formed.
The resin insulating portion is formed to be thicker in the circumferential direction on the central side than both end faces along the axial direction of the laminated iron core.
Further, the method for manufacturing an insulating structure of a rotary electric machine disclosed in the present application is described.
A laminated iron core formed by laminating steel plates is provided, and a resin insulating portion is integrally formed on the laminated iron core so as to cover at least a surface portion where a coil is wound, and the coil is wound on the resin insulating portion. the insulating structure of a rotating electric machine that is a process for the preparation,
A molding die for injection molding of the resin insulating portion is applied, and the inner wall of the molding die has a wall thickness in the circumferential direction on the central side of both end faces along the axial direction of the laminated iron core. A recess for forming a bulging portion is formed in advance, the laminated iron core is arranged inside the molding die, and then an insulating resin is injected from the resin injection port of the molding die to form the resin insulating portion. Is to be molded.
Further, the method for manufacturing an insulating structure of a rotary electric machine disclosed in the present application is described.
Provided with a laminated core in which a plurality of steel plates are laminated, the resin insulating portion covering the surface portion places the the laminated core is to be at least the coil is wound is assembled from two or more directions in the axial direction, the resin insulation wherein a coil manufacturing method of the insulating structure of the rotary electric machine that has been wound onto the part,
A molding mold for injection molding in which the resin insulating portion is divided into two or more directions in the axial direction is applied, and the inner wall of the mold of the molding mold is on the center side of both end faces along the axial direction of the laminated iron core. In the above, a concave portion for forming a bulging portion that becomes thicker in the circumferential direction was formed in advance, and an insulating resin was injected from the resin injection port of the molding mold to be divided into two or more directions in the axial direction. After molding the resin insulating portion and taking out the resin insulating portion divided into two or more directions in the axial direction from the molding mold, the resin insulating portion divided into two or more axial directions in the laminated iron core. Is assembled from two or more axial directions.

Claims (12)

In an insulating structure of a rotating electric machine, which is provided with a laminated iron core in which a plurality of steel plates are laminated, and a resin insulating portion is integrally formed on the laminated iron core by at least covering the surface portion of a portion where a coil is wound. ,
The resin insulating portion is an insulating structure of a rotating electric machine having a bulging portion formed thickly in the circumferential direction on the central side of both end surfaces along the axial direction of the laminated iron core. In the resin insulating portion, the maximum thickness of the portion formed on the axial end face of the laminated iron core is thicker than the maximum thickness of the portion formed along the axial direction of the laminated iron core, and the laminated iron core is formed. The insulating structure of a rotary electric machine according to claim 1, wherein a resin injection port mark is provided at a portion formed on an end face in the axial direction of the above. The insulating structure for a rotary electric machine according to claim 2, wherein the resin insulating portion has a uniform thickness at a portion where an end face in the axial direction of the laminated iron core is formed. From claim 1, the portion of the laminated iron core around which the coil is wound has a portion formed in which the circumferential length is shorter on the central side in the axial direction than the circumferential length on both ends in the axial direction. The insulating structure of a rotary electric machine according to any one of claims 3. Insulation of a rotary electric machine is provided with a laminated iron core in which a plurality of steel plates are laminated, and a resin insulating portion covering at least the surface portion of a portion where a coil is wound is assembled from two or more axial directions on the laminated iron core. In the structure
In the resin insulating portion, the maximum thickness of the portion formed on the axial end face of the laminated iron core is thicker than the maximum thickness of the portion formed along the axial direction of the laminated iron core, and the laminated iron core is formed. Has a resin injection port mark on the end face in the axial direction of
In the resin insulating portion, the thickness of the portion where the end face in the axial direction of the laminated iron core is formed is uniformly formed.
The resin insulating portion is an insulating structure of a rotating electric machine having a bulging portion formed thickly in the circumferential direction on the central side of both end surfaces along the axial direction of the laminated iron core. The insulating structure of a rotary electric machine according to any one of claims 1 to 5, wherein the bulging portion is provided within a range smaller than the winding bulging gap between the laminated iron core and the coil. .. The insulating structure of a rotary electric machine according to any one of claims 1 to 6, wherein the bulging portion is formed at a portion corresponding to a tooth side surface portion facing the laminated iron core in the circumferential direction. The method according to any one of claims 1 to 7, wherein the bulging portion has a semi-spindle-shaped cross section having a apex at the center in the axial direction and gradually decreasing in thickness toward both end faces. Insulation structure of rotary electric machine. The insulating structure of a rotary electric machine according to any one of claims 1 to 7, wherein the bulging portion has a trapezoidal cross section. The insulating structure of a rotary electric machine according to any one of claims 1 to 7, wherein the bulging portion has a protruding cross section. A method for manufacturing an insulating structure of a rotating electric machine, which is provided with a laminated iron core formed by laminating steel plates, and a resin insulating portion is integrally formed on the laminated iron core by at least covering the surface portion of a portion where a coil is wound. There,
A molding die for injection molding of the resin insulating portion is applied, and the inner wall of the molding die has a wall thickness in the circumferential direction on the central side of both end faces along the axial direction of the laminated iron core. A recess for forming a bulging portion is formed in advance, the laminated iron core is arranged inside the molding die, and then an insulating resin is injected from the resin injection port of the molding die to form the resin insulating portion. A method of manufacturing an insulating structure of a rotary electric machine for molding. Insulation of a rotary electric machine is provided with a laminated iron core in which a plurality of steel plates are laminated, and a resin insulating portion covering at least a surface portion where a coil is wound is assembled from two or more axial directions on the laminated iron core. It is a method of manufacturing a structure.
A molding mold for injection molding in which the resin insulating portion is divided into two or more directions in the axial direction is applied, and the inner wall of the mold of the molding mold is on the center side of both end faces along the axial direction of the laminated iron core. In the above, a concave portion for forming a bulging portion that becomes thicker in the circumferential direction was formed in advance, and an insulating resin was injected from the resin injection port of the molding mold to be divided into two or more directions in the axial direction. After molding the resin insulating portion and taking out the resin insulating portion divided into two or more directions in the axial direction from the molding mold, the resin insulating portion divided into two or more axial directions in the laminated iron core. A method for manufacturing an insulating structure of a rotary electric machine, which is assembled from two or more axial directions.

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