WO2019035400A1

WO2019035400A1 - Stator structure and brushless motor

Info

Publication number: WO2019035400A1
Application number: PCT/JP2018/029750
Authority: WO
Inventors: 幸嗣癸生川
Original assignee: ミネベアミツミ株式会社
Priority date: 2017-08-18
Filing date: 2018-08-08
Publication date: 2019-02-21
Also published as: JP2019037082A; JP6734238B2

Abstract

A stator structure (1) according to an embodiment is provided with: a stator core (10); a first insulator (20) and a second insulator (30); a plurality of coils; and a plurality of pins (40). The stator core (10) is configured by laminating thin band-like magnetic materials (10a) and has a plurality of teeth (12) extending radially from an annular main body part (11). The first insulator (20) and the second insulator (30) are made of resins and cover both sides of the stator core (10) in the axial direction. Each of the plurality of coils is wound on an extension part (12a) of the plurality of teeth (12) through the first insulator (20) and the second insulator (30). The plurality of pins (40) are formed integrally with at least one among the first insulator (20) and the second insulator (30), and couple the first insulator (20) and the second insulator (30).

Description

Stator structure and brushless motor

The present invention relates to a stator structure and a brushless motor.

Conventionally, as a means for forming a stator core that functions as an iron core of a motor, a technique is known in which a plurality of thin strips made of metal material are laminated while being bonded with an adhesive (see, for example, Patent Document 1).

Japanese Patent Application Publication No. 11-312604

However, in the prior art, the volume of the ribbon in the stator core is relatively reduced by the adhesive, which causes a problem that the magnetic properties of the stator core are degraded.

This invention is made in view of the above, Comprising: It aims at providing the stator structure and brushless motor which can improve the magnetic characteristic of a stator core.

In order to solve the problems described above and achieve the object, a stator structure according to an aspect of the present invention includes a stator core, a first insulator and a second insulator, a plurality of coils, and a plurality of pins. The stator core is formed by laminating thin ribbons of a magnetic material, and has a plurality of teeth radially extending from an annular main body. The first insulator and the second insulator are made of resin and cover both sides of the stator core in the axial direction. The plurality of coils are respectively wound around the extension parts of the plurality of teeth via the first insulator and the second insulator. The plurality of pins are integrally formed with at least one of the first insulator and the second insulator, and couple the first insulator and the second insulator.

According to one aspect of the present invention, the magnetic properties of the stator core can be improved.

FIG. 1 is a perspective view showing the configuration of the stator structure according to the embodiment. FIG. 2 is a cross-sectional perspective view taken along line AA in FIG. FIG. 3 is a diagram (1) for explaining an assembly process of the stator structure according to the embodiment. FIG. 4 is a diagram (2) for explaining an assembly process of the stator structure according to the embodiment. FIG. 5 is a diagram (3) for explaining the assembly process of the stator structure according to the embodiment.

Hereinafter, a stator structure and a brushless motor according to the embodiment will be described with reference to the drawings. The application of the stator structure and the brushless motor is not limited by the embodiments described below. In addition, it should be noted that the drawings are schematic, and the relationship between dimensions of each element, the ratio of each element, and the like may differ from reality. Furthermore, even between the drawings, there may be portions where dimensional relationships and proportions differ from one another.

(Configuration of stator structure)
First, details of the stator structure 1 according to the embodiment will be described with reference to FIGS. 1 and 2. FIG. 1 is a perspective view showing a configuration of a stator structure 1 according to the embodiment, and FIG. 2 is a cross-sectional perspective view taken along line AA in FIG.

As shown in FIG. 1, the stator structure 1 has a main body portion 2 having a substantially cylindrical shape, and a plurality of extending portions 3 extending in the radial direction from the main body portion 2. Then, in the stator structure 1, the circular hole portion 4 is formed in the central portion by the plurality of extending portions 3.

Then, an inner rotor type brushless motor is configured by arranging a rotor (not shown) in such a circular hole portion 4 in a freely rotatable state around the rotation axis R as an axis.

The stator structure 1 includes a stator core 10, a first insulator 20, a second insulator 30, a plurality of coils (not shown), and a plurality of pins 40.

The stator core 10 has a main body 11 and a plurality of teeth 12. The main body portion 11 is a portion corresponding to the main body portion 2 of the stator structure 1, and the teeth 12 are a portion corresponding to the extension portion 3 of the stator structure 1. Further, as shown in FIG. 2, the stator core 10 is configured by laminating a plurality of thin strips 10 a made of metal.

The first insulator 20 and the second insulator 30 are disposed so as to cover both sides of the stator core 10 in a direction parallel to the rotation axis R (hereinafter, also referred to as an axial direction). The first insulator 20 and the second insulator 30 are each formed by injection molding an insulating resin.

A plurality of coils (not shown) are respectively wound around the extension portions 3 of the stator structure 1. That is, the plurality of coils are respectively wound around the extending portions 12 a (see (b) of FIG. 3) of the plurality of teeth 12 via the first insulator 20 and the second insulator 30.

The plurality of pins 40 are provided along the axial direction, for example, on the inner peripheral side of the main body 2 in the stator structure 1 or on the tip side of the extension 3. The plurality of pins 40 are integrally molded with the second insulator 30 when the second insulator 30 is injection-molded. For example, it is conceivable that the second insulator 30 and the plurality of pins are integrally molded by injection molding as an integral part by using the same material as the second insulator 30, or by insert molding. When the pins are integrally formed by insert molding, the pins 40 may be made of a metal material.

Here, in the embodiment, by fixing the plurality of pins 40 to the first insulator 20, the first insulator 20 and the second insulator 30 are coupled. Thereby, as shown in FIG. 2, the plurality of thin ribbons 10 a are sandwiched and held by the first insulator 20 and the second insulator 30.

That is, in the stator structure 1 according to the embodiment, since the plurality of thin strips 10a can be held without the adhesive, the stator core 10 can be entirely formed of the thin strips 10a. Therefore, according to the embodiment, the magnetic characteristics of the stator core 10 can be improved.

In the embodiment, the thin strip 10a may be made of an amorphous metal material or a nanocrystalline soft magnetic material. Here, when the stator core 10 is configured by the thin strip 10a of the amorphous metal material or the nanocrystalline soft magnetic material, the thickness of the thin strip 10a can be reduced compared to the electromagnetic steel sheet, so iron loss at high speed rotation can be obtained. It can be further suppressed.

On the other hand, in the case of using an amorphous metal material or a nanocrystalline soft magnetic material, it is impossible to integrally hold the plurality of thin strips 10a by means such as welding or caulking as in the case of a magnetic steel sheet. However, in the embodiment, even when the ribbon 10a is made of an amorphous metal material or a nanocrystalline soft magnetic material, the stator core 10 can be formed without using a means such as welding or caulking.

Therefore, according to the embodiment, by configuring the ribbon 10a with an amorphous metal material or a nanocrystalline soft magnetic material, iron loss at high speed rotation can be further suppressed. As the amorphous metal material or the nanocrystalline soft magnetic material, for example, a Co-based material or an Fe-based material may be used. The thickness of the thin strip 10a may be, for example, about 25 μm.

(Assembly process of stator structure)
Subsequently, an assembly process of the stator structure 1 according to the embodiment will be described with reference to FIGS. 3 to 5. FIG. 3 is a diagram (1) for explaining an assembly process of the stator structure 1 according to the embodiment.

As shown in (a) to (c) of FIG. 3, in the stator structure 1, the first insulator 20, the stator core 10, and the second insulator 30 are stacked in order from above with the rotation axis R as the center. Can be assembled.

As shown to (a) of FIG. 3, the 1st insulator 20 has the cyclic | annular main-body part 21. As shown in FIG. Further, a side wall 22 projecting downward from the inner peripheral portion of the main body portion 21, a plurality of extending portions 23 extending inward in the radial direction from the inner peripheral portion of the main body portion 21, and an edge of the extending portion 23 And a side wall 24 projecting downward from the portion. Further, a plurality of notches 25 are formed on the inner peripheral side of the main body 21 corresponding to the position of the pin 40, the tip side of the extension 23 and the like.

As shown in (b) of FIG. 3, the stator core 10 has an annular main body portion 11. Further, a plurality of teeth 12 extending inward in the radial direction from the inner circumferential portion of the main body portion 11 are provided. The teeth 12 are substantially Y-shaped in a plan view, and extend in the radial direction from the inner peripheral portion of the main body 11 in the radial direction, and both sides in the circumferential direction from the tip of the extension 12a. And a protruding portion 12b protruding from the

As shown in (c) of FIG. 3, the second insulator 30 has an annular main portion 31. Further, a plurality of extending portions 32 extending inward in the radial direction from the inner peripheral portion of the main body portion 31, and a side wall 33 projecting upward from the inner peripheral portion of the main body portion 31 and an edge portion of the extending portion 32 Have. A plurality of pins 40 are embedded in the side wall 33 so as to protrude upward.

Then, in the assembly process of the stator structure 1, the teeth 12 of the stator core 10 are vertically sandwiched by the extending portion 23 of the first insulator 20 and the extending portion 32 of the second insulator 30. The details of the sandwiching process will be described with reference to FIG.

FIG. 4 is a diagram (2) for explaining an assembly process of the stator structure 1 according to the embodiment. FIG. 4 shows a cross section of the extension portion 3 of the stator structure 1 shown in FIG. As shown in (a) of FIG. 4, in the sandwiching step, first, the second insulator 30 is set in a predetermined jig 100.

Next, the plurality of ribbons 10 a are stacked on the second insulator 30. Here, as shown to (a) of FIG. 4, it laminates | stacks, inserting the thin strip 10a in the groove part 34 formed of the extension part 32 of the 2nd insulator 30, and the side wall 33. As shown in FIG.

Here, in the embodiment, as shown in FIG. 4A, the groove 34 may be formed so as to increase in width toward the opening. Thus, when the thin strip 10a is inserted into the groove 34, the thin strip 10a can be inserted into the groove 34 without any problem even if the position of the thin strip 10a is slightly shifted in the circumferential direction. Therefore, according to the embodiment, assembling workability of the stator structure 1 can be improved.

After stacking the thin strips 10 a in this manner, the first insulator 20 is covered from above the second insulator 30 to sandwich the stacked thin strips 10 a. At this time, the fitting portion 26 formed by the extension portion 23 of the first insulator 20 and the side wall 24 is fitted to the groove portion 34 from the outside of the groove portion 34 of the second insulator 30.

Here, in the embodiment, as shown in (a) of FIG. 4, the fitting portion 26 may be formed so as to increase in width toward the opening. Thereby, as shown to (b) of FIG. 4, when the 1st insulator 20 is pressed by the force 101, the thin strip 10a is made via the 1st insulator 20 and the 2nd insulator 30 on the basis of the jig 100. Is pressed by the force 102 from both sides.

By pressing from both sides in this manner, it is possible to align the positions of the thin ribbons 10a whose positions are shifted in the circumferential direction. Therefore, according to the embodiment, assembling workability of the stator structure 1 can be further improved.

Furthermore, by pressing from above with a force 101, the plurality of thin ribbons 10a can be stacked without a gap between the first insulator 20 and the second insulator 30. In the embodiment, since the convex portion 27 is provided on the inner wall of the extension portion 23 in the fitting portion 26, the force 101 can be efficiently transmitted to the laminate of the thin ribbons 10a.

Finally, the jig 100 is removed. By removing the jig 100, the force 102 is not applied on the side of the laminate of the ribbons 10a, but there is no particular problem because the laminate of the ribbons 10a is already held integrally by the force 101. .

Subsequently, a process of fixing the pin 40 to the first insulator 20 will be described with reference to FIG. FIG. 5 is a diagram (3) for explaining an assembly process of the stator structure 1 according to the embodiment.

As shown in FIG. 5, when the stator core 10 is held between the first insulator 20 and the second insulator 30, the tip 40 a of the pin 40 protrudes outward from the notch 25 formed in the first insulator 20. There is.

Here, in the embodiment, the pin 40 is fixed to the first insulator 20 by welding the tip portion 40a. As such a welding method, for example, infrared welding, ultrasonic welding or the like can be used.

Finally, the stator structure 1 is obtained by winding a winding having a predetermined number of turns around the extension portion 3 of the stator structure 1 assembled up to this point.

As mentioned above, although embodiment of this invention was described, this invention is not limited to the said embodiment, A various change is possible unless it deviates from the meaning. For example, although the embodiment shows an example in which the second insulator 30 and the plurality of pins 40 are integrally formed, the first insulator 20 and the plurality of pins 40 may be integrally formed. Further, both the first insulator 20 and the second insulator 30 may be integrally formed with the plurality of pins 40.

In the embodiment, the fitting portion 26 is formed in the first insulator 20, and the groove 34 is formed in the second insulator 30, but the groove is formed in the first insulator 20, and the second insulator 30 is formed. The fitting portion may be formed on the

In the embodiment, an example is shown in which the force 102 is applied to the side of the thin strip 10a with the jig 100 at the base point, but, for example, by increasing the strength of the first insulator 20, not the jig 100 but the first A force 102 can be applied to the sides of the ribbon 10a with the insulator 20 as a base point.

Furthermore, in the embodiment, the present invention is applied to the inner rotor type brushless motor, but the present invention may be applied to the outer rotor type brushless motor.

As described above, the stator structure 1 according to the embodiment includes the stator core 10, the first insulator 20 and the second insulator 30, the plurality of coils, and the plurality of pins 40. The stator core 10 is formed by laminating thin ribbons 10 a of magnetic material, and has a plurality of teeth 12 radially extending from an annular main body 11. The first insulator 20 and the second insulator 30 are made of resin and cover both sides of the stator core 10 in the axial direction. The plurality of coils are respectively wound around the extending portions 12 a of the plurality of teeth 12 via the first insulator 20 and the second insulator 30. The plurality of pins 40 are integrally formed with at least one of the first insulator 20 and the second insulator 30 to couple the first insulator 20 and the second insulator 30. Thereby, the magnetic characteristic of stator core 10 can be improved.

Further, in the stator structure 1 according to the embodiment, the groove portion 34 in which the extension portions 12 a of the plurality of teeth 12 are fitted is formed in one of the first insulator 20 and the second insulator 30. It is formed so that the width becomes wide according to heading. Thereby, the assembly workability of the stator structure 1 can be improved.

Further, in the stator structure 1 according to the embodiment, the fitting portion 26 fitted to the groove 34 from the outside of the groove 34 is formed on the other of the first insulator 20 and the second insulator 30. When the fitting portion 26 is fitted from the outside of the groove portion 34, the side surface of the fitting portion 26 is pressed from the fitting portion 26 via the groove portion 34. Thereby, the assembly workability of the stator structure 1 can be further improved.

In the stator structure 1 according to the embodiment, the thin strip 10a is made of an amorphous metal material or a nanocrystalline soft magnetic material. Thereby, the iron loss at the time of high speed rotation can be further suppressed.

In addition, the brushless motor according to the embodiment includes the above-described stator structure 1 and a rotor disposed rotatably inside the stator structure 1. Thereby, the brushless motor which improved the magnetic characteristic of stator core 10 is realizable.

Further, the present invention is not limited by the above embodiment. What is configured by appropriately combining the above-described constituents is also included in the present invention. Further, further effects and modifications can be easily derived by those skilled in the art. Therefore, the broader aspects of the present invention are not limited to the above embodiment, and various modifications are possible.

DESCRIPTION OF SYMBOLS 1 Stator structure, 10 Stator core, 10a thin strip, 11 main-body part, 12 teeth, 12a extension part, 20 1st insulator, 26 fitting part, 30 2nd insulator, 34 groove part, 40 pin

Claims

A stator core formed by laminating thin strips of magnetic material and having a plurality of teeth radially extending from an annular main body;
A first insulator and a second insulator made of resin covering both sides of the stator core in the axial direction;
A plurality of coils respectively wound around extension parts of the plurality of teeth via the first insulator and the second insulator;
A plurality of pins formed integrally with at least one of the first insulator and the second insulator and coupling the first insulator and the second insulator;
Stator structure, comprising:
In one of the first insulator and the second insulator, a groove is formed in which the extension of the plurality of teeth is fitted;
The stator structure according to claim 1, wherein the groove is formed so as to increase in width toward the opening.
The other of the first insulator and the second insulator is formed with a fitting portion to be fitted to the groove from the outside of the groove,
The stator structure according to claim 2, wherein the thin ribbon of the stator core has a side surface pressed from the fitting portion via the groove portion when the fitting portion is fitted from the outside of the groove portion.
The stator structure according to any one of claims 1 to 3, wherein the ribbon is made of an amorphous metal material or a nanocrystalline soft magnetic material.
The stator structure according to any one of claims 1 to 4;
A rotor rotatably disposed inside the stator structure;
, Brushless motor.