WO2020217375A1 - ステータ、モータ、送風機、空気調和装置およびステータの製造方法 - Google Patents
ステータ、モータ、送風機、空気調和装置およびステータの製造方法 Download PDFInfo
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- WO2020217375A1 WO2020217375A1 PCT/JP2019/017596 JP2019017596W WO2020217375A1 WO 2020217375 A1 WO2020217375 A1 WO 2020217375A1 JP 2019017596 W JP2019017596 W JP 2019017596W WO 2020217375 A1 WO2020217375 A1 WO 2020217375A1
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- WIPO (PCT)
- Prior art keywords
- insulator
- teeth
- axis
- stator
- maximum thickness
- Prior art date
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Classifications
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/32—Windings characterised by the shape, form or construction of the insulation
- H02K3/325—Windings characterised by the shape, form or construction of the insulation for windings on salient poles, such as claw-shaped poles
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/46—Fastening of windings on the stator or rotor structure
- H02K3/52—Fastening salient pole windings or connections thereto
- H02K3/521—Fastening salient pole windings or connections thereto applicable to stators only
- H02K3/522—Fastening salient pole windings or connections thereto applicable to stators only for generally annular cores with salient poles
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F7/00—Ventilation
- F24F7/007—Ventilation with forced flow
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
- H02K1/14—Stator cores with salient poles
- H02K1/146—Stator cores with salient poles consisting of a generally annular yoke with salient poles
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
- H02K15/022—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies with salient poles or claw-shaped poles
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/10—Applying solid insulation to windings, stators or rotors
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K21/00—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
- H02K21/12—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets
- H02K21/14—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets rotating within the armatures
- H02K21/16—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets rotating within the armatures having annular armature cores with salient poles
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
- H02K2203/12—Machines characterised by the bobbins for supporting the windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2213/00—Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
- H02K2213/03—Machines characterised by numerical values, ranges, mathematical expressions or similar information
Definitions
- the present invention relates to a stator, a motor, a blower, an air conditioner, and a method for manufacturing a stator.
- the stator has a stay core, an insulator, and a coil that is wound around the stator core via the insulator.
- the insulator is made of resin and is integrally molded with the stator core (see, for example, Patent Document 1).
- the present invention has been made to solve the above problems, and an object of the present invention is to reduce the thickness of the insulator.
- the stator of the present invention has a stator core having a yoke extending in the circumferential direction centered on the axis, teeth extending from the yoke toward the axis, an insulator having a winding portion surrounding the teeth, and an insulator winding portion. It has a coil wound around it.
- the insulator winding portion is located on one side of the teeth in the axial direction, a second end located on one side of the teeth, and a second end located on the other side of the teeth. It has a side part to be used.
- the first end has a maximum thickness T1 in the axial direction and the second end has a maximum thickness T2 in the axial direction.
- the side portion has a maximum thickness T3 in the circumferential direction.
- the maximum thicknesses T1, T2 and T3 satisfy T3 ⁇ T1 ⁇ T2.
- the insulator has a gate mark on the same side as the first end in the axial direction.
- the thickness of the first portion of the winding portion of the insulator that is, the portion near the gate of the molding die and where the resin has high fluidity is thin, the thickness of the insulator can be effectively reduced. it can.
- FIG. It is a partial cross-sectional view which shows the motor of Embodiment 1.
- FIG. It is sectional drawing which shows the motor of Embodiment 1.
- FIG. It is a perspective view which shows the stator of Embodiment 1.
- FIG. It is a top view which shows the stator of Embodiment 1.
- It is a perspective view which shows the insulator of Embodiment 1.
- FIG. It is sectional drawing which shows the tooth, the insulator and the coil of Embodiment 1.
- FIG. It is sectional drawing which shows the molding die for forming the insulator of Embodiment 1.
- FIG. It is sectional drawing of the molding die in the line segment VIII-VIII shown in FIG. It is sectional drawing which shows the molding die for molding the mold resin part of Embodiment 1.
- FIG. 1 It is a flowchart which shows the manufacturing process of the motor of Embodiment 1. It is a graph which shows the relationship between the thickness of an insulator and the motor efficiency. It is a graph which shows the relationship between the resin temperature at the time of molding, melt viscosity and fluidity. It is a graph which shows the relationship between a forming pressure and a flow length. The relationship between the maximum thicknesses T1, T2, and T3 of the first end portion, the second end portion, and the side portion of the insulator is shown in comparison between the first embodiment (A) and the comparative example (B). is there. It is sectional drawing which shows the tooth, the insulator and the coil of Embodiment 2. FIG. FIG. FIG.
- FIG 3A is a cross-sectional view showing a tooth, an insulator and a coil of the third embodiment
- FIGS. (B) and (C) are enlarged views of a corner portion of the insulator.
- FIG. 1 is a vertical sectional view showing a motor 100 according to the first embodiment of the present invention.
- the motor 100 is, for example, a brushless DC motor used in a blower of an air conditioner and driven by an inverter. Further, the motor 100 is an IPM (Interior Permanent Magnet) motor in which a magnet 55 is embedded in a rotor 5.
- IPM Interior Permanent Magnet
- the motor 100 has a rotor 5 having a shaft 7 and a mold stator 4 surrounding the rotor 5.
- the mold stator 4 has an annular stator 1 that surrounds the rotor 5 and a mold resin portion 40 that covers the stator 1.
- the shaft 7 is a rotation shaft of the rotor 5.
- the direction of the central axis C1 of the shaft 7 is referred to as "axial direction”.
- the circumferential direction centered on the central axis C1 of the shaft 7 is referred to as a “circumferential direction”, and is indicated by an arrow S in FIG. 2 and the like.
- the radial direction centered on the central axis C1 of the shaft 7 is referred to as "diameter direction”.
- a cross-sectional view in a cross section parallel to the axial direction is referred to as a vertical cross-sectional view.
- the shaft 7 projects from the mold stator 4 to the left side in FIG. 1, and an impeller 505 of a blower (FIG. 17 (A)) is attached to the attachment portion 7a formed on the protrusion. Therefore, the protruding side (left side in FIG. 1) of the shaft 7 is referred to as “load side”, and the opposite side (right side in FIG. 1) is referred to as "counter-load side”.
- FIG. 2 is a cross-sectional view showing a portion of the motor 100 excluding the mold resin portion 40 (FIG. 1).
- the rotor 5 includes a shaft 7 which is a rotation shaft, a rotor core 50 provided at a distance outward in the radial direction from the shaft 7, a plurality of magnets 55 embedded in the rotor core 50, and the shaft 7 and the rotor core 50. It has a resin portion 6 provided between the two.
- the rotor core 50 is an annular member centered on the central axis C1, and the inner circumference of the rotor core 50 faces the shaft 7 at a distance.
- the rotor core 50 is formed by laminating a plurality of laminated elements in the axial direction and fixing them by caulking, welding, or bonding.
- the laminated element is, for example, an electromagnetic steel plate, and has a thickness of 0.2 mm to 0.5 mm.
- the rotor core 50 has a plurality of magnet insertion holes 51 in the circumferential direction.
- the magnet insertion holes 51 are arranged equidistantly in the circumferential direction and equidistant from the central axis C1.
- the number of magnet insertion holes 51 is 10 here.
- the magnet insertion hole 51 is formed along the outer circumference of the rotor core 50, and extends the rotor core 50 from one end to the other end in the axial direction.
- the magnet 55 is inserted into each magnet insertion hole 51.
- the magnet 55 is also referred to as a main magnet.
- the magnet 55 has a flat plate shape, has a thickness in the radial direction, and is magnetized in the thickness direction.
- Each magnet 55 constitutes a magnetic pole.
- the number of magnets 55 is 10, and therefore the number of poles of the rotor 5 is 10.
- the number of poles of the rotor 5 is not limited to 10 poles, and may be 2 poles or more.
- the circumferential center of the magnet insertion hole 51 is the pole center, and the space between the adjacent magnet insertion holes 51 is the pole.
- the magnet 55 is a rare earth magnet, and more specifically, a neodymium magnet containing Nd (neodymium), Fe (iron) and B (boron), or a samarium cobalt magnet containing Sm (samarium) and Co (cobalt). is there.
- a ferrite magnet containing Fe may be used instead of the rare earth magnet.
- one magnet 55 is arranged in one magnet insertion hole 51 here, two or more magnets 55 may be arranged in one magnet insertion hole 51.
- Flux barriers 52 which are voids, are formed at both ends of the magnet insertion hole 51 in the circumferential direction.
- the flux barrier 52 suppresses a short circuit of magnetic flux between adjacent magnets 55.
- a core hole 54 is formed inside the rotor core 50 in the radial direction with respect to the magnet insertion hole 51.
- the core hole 54 is formed here at a position corresponding to the polar center.
- the core hole 54 is formed in order to reduce the core material of the rotor core 50, but it does not necessarily have to be formed.
- the rotor core 50 has a so-called flower-round outer circumference in which the outer diameter is the largest at the pole center of each magnetic pole and the outer diameter is the smallest between the poles in a cross section orthogonal to the axial direction.
- the outer circumference of the rotor core 50 is not limited to such a flower circle shape, and may be a circular shape.
- a resin portion 6 is provided between the shaft 7 and the rotor core 50.
- the resin portion 6 holds the shaft 7 and the rotor core 50 in a state of being separated from each other, and is formed of a non-magnetic material.
- the resin portion 6 is formed of a thermoplastic resin such as PBT (polybutylene terephthalate).
- the core hole 54 of the rotor core 50 is also filled with the same resin as the resin portion 6 to form the filling portion 61.
- the resin portion 6 also covers both ends in the axial direction of the rotor core 50.
- the resin portion 6 holds the sensor magnet 56 on the opposite load side of the rotor core 50.
- the sensor magnet 56 is an annular magnet centered on the axis C1 and has the same number of magnetic poles as the magnet 55.
- the sensor magnet 56 is magnetized in the axial direction. The magnetic flux of the sensor magnet 56 is detected by the magnetic sensor 44 described later.
- the shaft 7 may be fitted into the center hole of the rotor core 50 without providing the resin portion 6.
- IPM Inner Permanent Magnet
- SPM Surface Permanent Magnet
- the mold stator 4 has the stator 1 and the mold resin portion 40.
- the mold resin portion 40 is formed of a thermosetting resin such as BMC (bulk molding compound).
- BMC bulk molding compound
- the mold resin portion 40 has an opening 41 on the load side and a bearing support portion 42 on the non-load side.
- the rotor 5 is inserted through the opening 41 into the hollow portion inside the mold stator 4.
- a metal bracket 73 is attached to the opening 41 of the mold resin portion 40.
- the bracket 73 holds one bearing 71 that supports the shaft 7.
- a cap 74 is attached to the outside of the bracket 73.
- the bearing support portion 42 of the mold resin portion 40 has a cylindrical inner peripheral surface, and the other bearing 72 that supports the shaft 7 is held on the inner peripheral surface.
- the circuit board 43 is held on the opposite load side of the stator 1.
- the circuit board 43 is a printed circuit board on which a drive circuit such as a power transistor for driving the motor 100 is mounted, and a lead wire 45 is wired.
- the lead wire 45 of the circuit board 43 is pulled out from the lead wire lead-out component 46 attached to the outer peripheral portion of the mold resin portion 40 to the outside of the motor 100.
- a magnetic sensor 44 is attached to the surface of the circuit board 43 on the stator 1 side so as to face the sensor magnet 56 in the axial direction.
- the magnetic sensor 44 is composed of, for example, a Hall effect element, an MR (Magnet Resistive) element, a GMR (Giant Magneto Resistive) element, or a magnetic impedance element.
- the magnetic sensor 44 outputs a binary signal when it faces the north pole of the sensor magnet 56 and when it corresponds to the south pole. From the output signal of the magnetic sensor 44, the position of the magnet 55, that is, the rotation position of the rotor 5 is detected.
- sensorless control may be performed without providing the sensor magnet 56 and the magnetic sensor 44 to estimate the rotational position of the rotor 5 based on the current or voltage flowing through the coil 3.
- the bracket 73 is press-fitted into the annular portion provided on the outer peripheral edge of the opening 41 of the mold resin portion 40.
- the bracket 73 is made of a conductive metal, for example, a galvanized steel sheet.
- the cap 74 is attached to the outside of the bracket 73 to prevent water or the like from entering the bearing 71.
- the periphery of the stator 1 is covered with a mold resin portion 40, but instead of providing the mold resin portion 40, the outer circumference of the stator 1 is fitted inside a cylindrical shell made of metal. May be good.
- the stator 1 surrounds the rotor 5 from the outside in the radial direction.
- the stator 1 has a stator core 10, an insulator 2 provided on the stator core 10, and a coil 3 wound around the stator core 10 via the insulator 2.
- the stator core 10 is formed by laminating a plurality of laminated elements in the axial direction and fixing them by caulking, welding, or bonding.
- the laminated element is, for example, an electromagnetic steel plate.
- the thickness of the laminated steel sheet is, for example, 0.2 mm to 0.5 mm.
- the stator core 10 has a yoke 11 extending annularly in the circumferential direction about the central axis C1 and a plurality of teeth 12 extending radially inward from the yoke 11 (toward the central axis C1).
- a slot 13 is formed between adjacent teeth 12.
- the radial inner tip surface (tip surface 12e shown in FIG. 3) of the teeth 12 faces the outer peripheral surface of the rotor 5.
- the number of teeth 12 is 9 here. However, the number of teeth 12 is not limited to 9, and may be 2 or more.
- the yoke 11 and the teeth 12 are provided with caulking portions 18 and 19 for fixing the plurality of laminated elements described above.
- the arrangement of the caulking portion is not limited to these positions.
- the laminated element is not limited to caulking, and may be fixed by welding or adhesion.
- the stator core 10 has a configuration in which each tooth 12 is divided into a plurality of connecting cores 10A.
- the connecting core 10A is divided by a dividing surface 14 formed on the yoke 11.
- the dividing surface 14 extends radially outward from the inner peripheral surface of the yoke 11.
- a plastically deformable thin-walled portion is formed between the end of the dividing surface 14 and the outer peripheral surface of the yoke 11.
- the stator core 10 can be expanded in a strip shape by the plastic deformation of the thin portion.
- the stator core 10 is not limited to a combination of the connecting cores 10A, and may be an annular laminated steel plate laminated in the axial direction.
- a resin insulator 2 is provided so as to surround the teeth 12 of the stator core 10.
- the coil 3 is composed of a magnet wire and is wound around the teeth 12 via an insulator 2.
- the coil 3 is housed in a slot 13 between adjacent teeth 12.
- ⁇ Structure of insulator 2> 3 and 4 are a perspective view and a top view showing the stator core 10 and the insulator 2.
- the insulator 2 is formed of an insulating resin, for example, a thermoplastic resin such as PBT (polybutylene terephthalate), PPS (polyphenylene sulfide), LCP (liquid crystal polymer), PET (polyethylene terephthalate) and the like.
- the insulator 2 is formed by integrally molding the resin with the stator core 10 or by assembling the resin molded body to the stator core 10.
- stator core 10 is composed of the connecting core 10A (FIG. 2) as described above, the insulator 2 is integrally molded with the teeth 12 in a state where the stator core 10 is spread out in a strip shape, and the insulator 2 is formed into the teeth 12 via the insulator 2.
- the coil 3 can be wound.
- FIG. 5 is a perspective view showing one tooth 12 of the stator core 10 and an insulator 2 surrounding the tooth 12.
- the insulator 2 includes a winding portion 21 that surrounds the teeth 12 from both sides in the circumferential direction and both sides in the axial direction, an inner side wall portion 22 adjacent to the radial inner side of the winding portion 21, and an outer wall portion adjacent to the radial outer side of the winding portion 21. It has 23 and.
- the inner side wall portion 22 is provided at the tip portion on the inner side in the radial direction of the teeth 12.
- the outer side wall portion 23 is provided so as to straddle the root portion on the outer side in the radial direction of the tooth 12 and the yoke 11.
- the inner side wall portion 22 and the outer wall portion 23 face each other in the radial direction.
- a coil 3 (FIG. 3) is wound around the winding portion 21.
- the inner side wall portion 22 and the outer wall portion 23 guide the coil 3 from both sides in the radial direction.
- the winding portion 21 has a first end portion 21a located on one side of the teeth 12 in the axial direction, a second end portion 21b located on the other side of the teeth 12 in the axial direction, and the teeth 12 in the circumferential direction. It has a pair of side portions 21c located on both sides of the.
- the inner side wall portion 22 has a first wall portion 22a located on one side of the teeth 12 in the axial direction, a second wall portion 22b located on the other side of the teeth 12 in the axial direction, and teeth in the circumferential direction. It has a pair of side wall portions 22c located on both sides of the twelve.
- the outer side wall portion 23 includes a first wall portion 23a located on one side of the teeth 12 in the axial direction, a second wall portion 23b located on the other side of the teeth 12 in the axial direction, and teeth in the circumferential direction. It has a pair of side wall portions 23c located on both sides of the twelve.
- the first end 21a of the winding portion 21, the first wall portion 22a of the inner side wall portion 22, and the first wall portion 23a of the outer wall portion 23 are on the same side in the axial direction. Further, the second end portion 21b of the winding portion 21, the second wall portion 2b of the inner side wall portion 22, and the second wall portion 23b of the outer wall portion 23 are on the same side in the axial direction.
- a gate mark G is formed on the first wall portion 22a of the inner side wall portion 22.
- the gate mark G is a portion corresponding to the gate 313 of the molding die used for molding the insulator 2.
- the gate mark G is formed as, for example, a concave portion or a convex portion on the radial inner surface of the first wall portion 22a of the inner side wall portion 22.
- FIG. 6 is a cross-sectional view showing the teeth 12, the winding portion 21 of the insulator 2, and the coil 3.
- FIG. 6 is a cross-sectional view of a plane orthogonal to the extending direction of the teeth 12.
- the teeth 12 has a rectangular cross-sectional shape in a cross section orthogonal to the extending direction thereof.
- the axial end faces 12a and 12b of the teeth 12 are covered with the first end portion 21a and the second end portion 21b of the winding portion 21.
- the circumferential end surface 12c of the teeth 12 is covered with the side portion 21c of the winding portion 21.
- the first end 21a of the winding portion 21 has a maximum thickness T1 in the axial direction. That is, the first end portion 21a of the winding portion 21 has an outer peripheral surface 211 on the side opposite to the end surface 12a of the teeth 12. The maximum distance from the end surface 12a of the teeth 12 to the outer peripheral surface 211 is the maximum thickness T1.
- the outer peripheral surface 211 of the first end portion 21a is shown as a curved surface that is convex on the side opposite to the teeth 12 in the axial direction, but may be a flat surface.
- the second end 21b of the winding portion 21 has a maximum thickness T2 in the axial direction. That is, the second end portion 21b of the winding portion 21 has an outer peripheral surface 212 on the side opposite to the end surface 12b of the teeth 12. The maximum distance from the end surface 12b of the teeth 12 to the outer peripheral surface 212 is the maximum thickness T2.
- the outer peripheral surface 212 of the second end portion 21b is shown as a curved surface that is convex on the side opposite to the teeth 12 in the axial direction, but may be a flat surface.
- the side portion 21c of the winding portion 21 has a maximum thickness T3 in the circumferential direction.
- the thickness of the side portion 21c is constant in the axial direction, but it does not necessarily have to be constant.
- the maximum thicknesses T1, T2, and T3 of each portion 21a, 21b, and 21c of the winding portion 21 satisfy T3 ⁇ T1 ⁇ T2.
- the maximum thickness T1 of the first end portion 21a on the same side as the gate mark G in the axial direction is larger than the maximum thickness T2 of the second end portion 21b on the side opposite to the gate mark G. thin. Further, the maximum thickness T3 of the side portion 21c is further thinner than the maximum thicknesses T1 and T2.
- FIG. 7 is a diagram showing a molding die 30 for molding the insulator 2.
- the molding die 30 has an upper mold 31 which is a movable mold and a lower mold 32 which is a fixed mold, and a cavity 33 is formed between them.
- the stator core 10 is installed in the cavity 33 in a strip-shaped state.
- a molding space 34 is formed for each tooth 12 of the stator core 10.
- a core 38 for securing a space for arranging the coil 3 (FIG. 6) is arranged on both sides of each tooth 12 in the cavity 33.
- stator core 10 spread in a band shape is installed in the cavity 33 here, an annular stator core 10 may be installed.
- the upper mold 31 has a spool 311 for injecting resin into the cavity 33, a runner 312, and a gate 313.
- the spool 311 is a flow path through which the molten resin flows from the cylinder 315, which is an injection device.
- the gate 313 is an injection port provided corresponding to each tooth 12 in the cavity 33.
- the runner 312 is a flow path that branches from the spool 311 and connects to each gate 313.
- FIG. 8 is a cross-sectional view of the line segment VIII-VIII shown in FIG. 7 in the direction of the arrow.
- the cavity 33 has a winding portion area 35 for forming the winding portion 21 of the insulator 2, an inner side wall portion area 36 for forming the inner side wall portion 22, and an outer wall portion area for forming the outer wall portion 23. It has 37 and.
- the gate 313 described above is open to a portion 361 forming the first wall portion 22a (FIG. 5) of the inner side wall portion 22 in the inner side wall portion area 36 of the cavity 33.
- the resin injected into the cavity 33 from the gate 313 has a second end 21b and a second wall 22b from the side forming the first end 21a and the first wall 22a, 23a (FIG. 5). , 23b (FIG. 5) flows toward the forming side.
- FIG. 9 is a cross-sectional view showing a molding die 80 used when the stator 1 and the shaft 7 are integrally molded with the molding resin.
- the molding die 80 includes an upper mold 81 which is a movable mold and a lower mold 82 which is a fixed mold, and a cavity 83 is formed between them.
- the lower mold 82 is formed with a gate 84 for injecting resin into the cavity 83.
- the lower mold 82 is formed with a columnar core 85 projecting into the cavity 83.
- the core 85 is a portion that engages with the inside of the stator core 10.
- a large diameter portion 86 is formed so as to project radially outward from the core 85.
- the large diameter portion 86 is a portion corresponding to the opening 41 (FIG. 1) of the mold stator 4.
- FIG. 10 is a flowchart showing a manufacturing process of the motor 100. First, a plurality of laminated elements are laminated in the axial direction and fixed by caulking or the like to form the stator core 10 (step S101).
- step S102 the insulator 2 is integrally molded with the stator core 10 (step S102). That is, the upper mold 31 of the molding die 30 shown in FIGS. 7 and 8 is moved upward to open the cavity 33, and the stator core 10 is installed in the cavity 33. After that, the upper mold 31 is moved downward to close the cavity 33. In this state, a molten resin such as PBT is injected from the cylinder 315 into the cavity 33 via the spool 311 and the runner 312 and the gate 313.
- the resin in the cavity 33 is cured by cooling the molding die 30.
- the resin cured in the winding portion area 35 becomes the winding portion 21
- the resin cured in the inner side wall portion area 36 becomes the inner side wall portion 22
- the resin cured in the outer wall portion area 37 becomes the outer wall portion 23.
- the upper mold 31 of the molding mold 30 is moved upward to open the cavity 33, and the stator core 10 in which the insulator 2 is integrally molded is taken out.
- the coil 3 is wound around the stator core 10 via the insulator 2 (step S103). At this stage, since the stator core 10 is spread out in a strip shape, the coil 3 can be easily wound.
- stator core 10 After winding the coil 3, the stator core 10 is bent in an annular shape and welded at both ends to form the stator 1 shown in FIG.
- step S104 the circuit board 43 is attached to the stator 1 and these are installed in the molding die 80 to form the mold resin portion 40 (step S104). That is, the upper mold 81 of the molding die 80 shown in FIG. 9 is moved upward to open the cavity 83, and the stator 1 is installed in the cavity 83. After that, the upper mold 81 is moved downward to close the cavity 83, and a mold resin such as BMC is injected into the cavity 83 from the gate 84. The mold resin injected into the cavity 83 covers the outer peripheral side and the unloaded side of the stator 1.
- the mold resin in the cavity 83 is cured by injecting the mold resin into the cavity 83 and then heating the molding mold 80. As a result, the production of the mold stator 4 in which the stator 1 is covered with the mold resin portion 40 is completed.
- the rotor 5 is formed separately from steps S101 to S104. That is, a plurality of laminated elements are laminated in the axial direction and fixed by caulking or the like to form the rotor core 50, and the magnet 55 is inserted into the magnet insertion hole 51. Further, the shaft 7, the rotor core 50, the magnet 55, and the sensor magnet 56 are integrally molded with the resin to be the resin portion 6. As a result, the rotor 5 is formed.
- step S106 the bearings 71 and 72 are attached to the shaft 7 of the rotor 5 and inserted into the inner portion of the stator 1 through the opening 41 of the mold stator 4 (step S106). Further, the bracket 73 is attached to the opening 41 of the mold stator 4, and the cap 74 is attached to the outside of the bracket 15. As a result, the production of the motor 100 shown in FIG. 1 is completed.
- steps S101 to S104 correspond to the manufacturing process of the stator 1 (manufacturing method of the stator 1).
- the resistance R of the coil 3 is represented by ⁇ ⁇ L / S using the resistivity ⁇ of the coil 3, the length L, and the cross-sectional area S. That is, the resistance R of the coil 3 increases in proportion to the length L of the coil 3. Therefore, the shorter the length per circumference of the coil 3 wound around the teeth 12 (hereinafter referred to as the winding length), the smaller the resistance R becomes.
- the smaller the resistance R the smaller the copper loss, which is one of the motor losses, and the higher the motor efficiency. In order to shorten the winding length of the coil 3, it is effective to reduce the thickness of the winding portion 21 of the insulator 2 around which the coil 3 is wound.
- the number of turns of the coil 3 affects the maximum output of the motor 100, in general, after determining the number of turns of the coil 3, the wire diameter as large as possible within the range that can be accommodated in the slot 13 is selected.
- reducing the maximum thicknesses T1 and T2 of the first end 21a and the second end 21b of the winding portion 21 only contributes to shortening the winding length of the coil 3. That is, the maximum thickness T3 in the circumferential direction contributes more to the improvement of motor efficiency than the maximum thickness T1 and T2 in the axial direction of the winding portion 21.
- FIG. 11 shows the simulation results regarding the contribution of the maximum thicknesses T1, T2, and T3 to the improvement of motor efficiency.
- the motor efficiency is the ratio (%) of the output (rotation speed x torque) to the electric power input to the motor 100.
- the line segment E1 shows a change in motor efficiency when the maximum thicknesses T1 and T2 are fixed at 1 mm and the maximum thickness T3 is changed.
- the line segment E2 shows a change in motor efficiency when the maximum thickness T3 is constant at 0.4 mm and the maximum thicknesses T1 and T2 are changed.
- the line segment E3 shows a change in motor efficiency when the maximum thickness T2 is 1 mm and the maximum thickness T3 is 0.4 mm, respectively, and the maximum thickness T1 is changed.
- the line segment E4 shows a change in motor efficiency when the maximum thickness T1 is 1 mm and the maximum thickness T3 is 0.4 mm, respectively, and the maximum thickness T2 is changed.
- the maximum thickness T3 of the side portion 21c is made the thinnest, that is, T3 ⁇ T1, T2.
- the maximum thickness T3 of the side portion 21c of the winding portion 21 is affected by the positional accuracy of the stator core 10 installed in the molding die 30, there is a limit to reducing the maximum thickness T3. Therefore, in addition to the maximum thickness T3, it is necessary to reduce the maximum thickness T1 of the first end portion 21a or the maximum thickness T2 of the second end portion 21b.
- thermoplastic resin is heated by the cylinder 315 to be in a molten state, and is injected from the spool 311 into the cavity 33 via the runner 312 and the gate 313. Cylinder.
- the temperature of the molding die 30 is significantly lower than the temperature of the cylinder 315, and the temperature of the stator core 10 is lower than the temperature of the molding die 30. Therefore, the temperature of the resin decreases as the resin flows through the spool 311 and the runner 312 and the gate 313.
- FIG. 12 shows the relationship between the temperature of the thermoplastic resin and the viscosity and fluidity. From FIG. 12, it can be seen that the viscosity and fluidity decrease as the temperature of the resin decreases.
- FIG. 13 shows the relationship between the molding pressure and the flow length for the three resin thicknesses Ta, Tb, and Tc (Ta ⁇ Tb ⁇ Tc). From FIG. 13, it can be seen that the higher the molding pressure, the longer the flow length, but when the resin thickness is thin, the rate of increase in the flow length due to the molding pressure is small.
- the gate 313 is open in the cavity 33 to the portion 361 forming the first wall portion 22a (FIG. 5) of the inner side wall portion 22.
- the thickness of the side portion 21c is the narrowest. Therefore, when the resin passes through the portion of the cavity 33 that forms the side portion 21c of the winding portion 21, the heat of the resin is taken away by the molding die 30 and the stator core 10, the temperature is lowered, and the resin is partially removed. There is a possibility of hardening, and it is difficult for the molding pressure to be uniformly transmitted to the entire area of the cavity 33.
- the gate 313 side of the cavity 33 has a higher fluidity of the resin than the side opposite to the gate 313 and is suitable for thinning.
- the maximum thickness T1 of the first end portion 21a near the gate 313 is made thinner than the maximum thickness T2 of the second end portion 21b far from the gate 313. That is, the maximum thicknesses T1, T2, and T3 satisfy T3 ⁇ T1 ⁇ T2, and the insulator 2 is thinned.
- FIG. 14 shows a first embodiment in which the maximum thicknesses T1, T2, and T3 of the insulator 2 satisfy T3 ⁇ T1 ⁇ T2, and a comparative example in which the maximum thicknesses T3 ⁇ T2 ⁇ T1 are satisfied. It is a schematic diagram which shows how thin T3 can be made.
- the second end 21b of the winding portion 21 is far from the gate 313, and the fluidity of the resin is low. Therefore, if an attempt is made to reduce the maximum thickness T2 of the second end portion 21b, the resin does not sufficiently spread to the second end portion 21b, resulting in molding defects.
- the maximum thickness T1 of the first end portion 21a can be effectively reduced.
- the gate 313 is formed as a concave or convex gate mark G on the surface of the first wall portion 22a (FIG. 5) of the inner side wall portion 22 of the insulator 2.
- the gate mark G is not limited to the first wall portion 22a of the inner side wall portion 22, and may be formed on the first wall portion 23a of the outer wall portion 23.
- the winding portion 21 of the insulator 2 has a first end portion 21a located on one side in the circumferential direction of the teeth 12 and a second end located on the other side. It has a portion 21b and a side portion 21c located on one side of the teeth 12 in the circumferential direction.
- the maximum thickness T1 in the axial direction of the first end portion 21a, the maximum thickness T2 in the axial direction of the second end portion 21b, and the maximum thickness T3 in the circumferential direction of the side portion 21c are T3 ⁇ T1 ⁇ . Satisfy T2.
- the insulator 2 has a gate mark G on the same side as the first end portion 21a in the axial direction. Therefore, the thickness of the insulator 2 can be effectively reduced, and as a result, the winding density of the coil 3 can be improved and the motor efficiency can be improved.
- FIG. 15 is a cross-sectional view showing the teeth 12 in the second embodiment, the winding portion 21 of the insulator 2A, and the coil 3.
- the winding portion 21 of the insulator 2A has a first end portion 21a, a second end portion 21b, and a side portion 21c, as in the first embodiment.
- the maximum thicknesses T1, T2, and T3 of the first end portion 21a, the second end portion 21b, and the side portion 21c of the winding portion 21 of the insulator 2A are T3 ⁇ T1 ⁇ T2.
- the gate mark G (FIG. 5) is on the same side as the first end portion 21a in the axial direction.
- the outer peripheral surface 211 of the first end portion 21a is a curved surface that is convex on the side opposite to the teeth 12 in the axial direction.
- the outer peripheral surface 211 is also an arcuate surface having a radius of curvature RT1 in a plane orthogonal to the extending direction of the teeth 12.
- the outer peripheral surface 212 of the second end portion 21b is a curved surface that is convex on the side opposite to the teeth 12 in the axial direction.
- the outer peripheral surface 212 is also an arcuate surface having a radius of curvature RT2 in a plane orthogonal to the extending direction of the teeth 12.
- the radius of curvature RT1 of the outer peripheral surface 211 of the first end 21a and the radius of curvature RT2 of the outer peripheral surface 212 of the second end 21b satisfy RT1> RT2.
- the thickness of the corner 213 between the first end 21a and the side 21c may be too thin. is there. Therefore, the resin does not spread over the entire insulator 21A during molding, and molding defects may occur.
- the radius of curvature RT1 of the outer peripheral surface 211 of the first end 21a is larger than the radius of curvature RT2 of the outer peripheral surface 212 of the second end 21b. Therefore, even if the maximum thickness T1 of the first end portion 21a of the winding portion 21 is thinned, the corner portion 213 is not too thin and the occurrence of molding defects is suppressed.
- the motor of the second embodiment is configured in the same manner as the motor 100 of the first embodiment except for the above-mentioned points.
- the radius of curvature RT1 of the outer peripheral surface 211 of the first end 21a of the winding portion 21 of the insulator 2A and the radius of curvature RT2 of the outer peripheral surface 212 of the second end 21b RT1> RT2 is satisfied. Therefore, the maximum thickness T1 of the first end portion 21a of the winding portion 21 of the insulator 2A can be further reduced without causing molding defects. As a result, the winding density of the coil 3 can be improved and the motor efficiency can be improved.
- outer peripheral surface 211 of the first end portion 21a and the outer peripheral surface 212 of the second end portion 21b are arcuate curved surfaces, but if the curved surface has a radius of curvature defined, it is not necessarily arcuate. It does not have to be.
- the maximum thicknesses T1, T2, and T3 of the winding portion 21 of the insulator 2A satisfy T3 ⁇ T1 ⁇ T2, but in the second embodiment, if RT1> RT2 and T1 ⁇ T2 are satisfied, the maximum thickness is satisfied.
- the effect of thinning T1 can be obtained.
- FIG. 16A is a cross-sectional view showing the teeth 12 in the third embodiment, the winding portion 21 of the insulator 2B, and the coil 3.
- the winding portion 21 of the insulator 2B has a first end portion 21a, a second end portion 21b, and a side portion 21c, as in the first embodiment.
- the maximum thicknesses T1, T2, and T3 of the first end portion 21a, the second end portion 21b, and the side portion 21c of the winding portion 21 of the insulator 2B are T3 ⁇ T1 ⁇ T2.
- the gate mark G (FIG. 5) is on the same side as the first end portion 21a in the axial direction.
- the insulator 2B of the third embodiment has a corner portion 213 as a first corner portion between the first end portion 21a and the side portion 21c. As shown enlarged in FIG. 16C, the corner portion 213 is an arcuate surface having a radius of curvature R1 in a plane orthogonal to the extending direction of the teeth 12.
- the insulator 2B also has a corner portion 214 as a second corner portion between the second end portion 21b and the side portion 21c. As shown enlarged in FIG. 16B, the corner portion 214 is an arcuate surface having a radius of curvature R2 in a plane orthogonal to the extending direction of the teeth 12.
- the radius of curvature R1 of the corner portion 213 and the radius of curvature R2 of the corner portion 214 satisfy R1 ⁇ R2.
- the corner portions 213 and 214 of the winding portion 21 are all curved surfaces due to the limitation of the mold shape.
- the teeth 12 is composed of a laminated body of punched laminated steel plates, all four corners in the cross section of the teeth 12 are at right angles.
- the thickness of the corner portion 213 covering the corner portion of the teeth 12 may become too thin when the maximum thickness T1 of the first end portion 21a is thinned. There is sex. That is, there is a possibility that the resin does not spread over the entire insulator 2B during molding.
- the radius of curvature R1 of the corner portion 213 on the first end portion 21a side is smaller than the radius of curvature R2 of the corner portion 214 on the second end portion 21b side. Therefore, the thickness of the corner portion 213 covering the corner portion of the tooth 12 does not become too thin, and the occurrence of molding defects can be suppressed.
- radius of curvature R1 of the corner portion 213 and the maximum thickness T1 of the first end portion 21a satisfy R1 ⁇ T1.
- the thickness of the portion 213 may be thinner than the thickness of the side portion 21c. That is, there is a possibility that the resin does not spread over the entire insulator 2B during molding.
- the radius of curvature R1 of the corner portion 213 is equal to or less than the maximum thickness T1 of the first end portion 21a. Therefore, even when the outer peripheral surface 211 of the first end portion 21a is close to a flat surface, the thickness of the corner portion 213 can be maintained at a thickness capable of resin molding.
- the outer peripheral surfaces 211 and 212 of the first end portion 21a and the second end portion 21b may be formed into an arcuate curved surface, and the respective radii of curvature RT1 and RT2 (FIG. 15). ) May satisfy RT1> RT2.
- the motor of the third embodiment is configured in the same manner as the motor 100 of the first embodiment except for the above-mentioned points.
- the radius of curvature R1 of the corner portion 213 between the first end portion 21a and the side portion 21c is the angle between the second end portion 21b and the side portion 21c. It is smaller than the radius of curvature R2 of the portion 214. Therefore, the maximum thickness T1 of the first end portion 21a of the winding portion 21 of the insulator 2B can be further reduced while suppressing the occurrence of molding defects. As a result, the winding density of the coil 3 can be improved and the motor efficiency can be improved.
- FIG. 17A is a diagram showing a configuration of an air conditioner 500 to which the motor 100 of the first embodiment is applied.
- the air conditioner 500 includes an outdoor unit 501, an indoor unit 502, and a refrigerant pipe 503 connecting them.
- the outdoor unit 501 includes, for example, an outdoor blower 510 that is a propeller fan
- the indoor unit 502 includes, for example, an indoor blower 520 that is a cross-flow fan.
- the outdoor blower 510 has an impeller 505 and a motor 100 for driving the impeller 505.
- the indoor blower 520 has an impeller 521 and a motor 100 for driving the impeller 521.
- Each of the motors 100 has the configuration described in the first embodiment.
- FIG. 17A also shows a compressor 504 that compresses the refrigerant.
- FIG. 17B is a cross-sectional view of the outdoor unit 501.
- the motor 100 is supported by a frame 509 arranged in the housing 508 of the outdoor unit 501.
- An impeller 505 is attached to the shaft 7 of the motor 100 via a hub 506.
- the impeller 505 attached to the shaft 7 rotates due to the rotation of the rotor 5 of the motor 100, and blows air to the outside.
- the heat released when the refrigerant compressed by the compressor 504 is condensed by the condenser (not shown) is released to the outside by the blower of the outdoor blower 510.
- the impeller 521 is rotated by the rotation of the rotor 5 of the motor 100, and the air deprived of heat by the evaporator (not shown) is blown into the room. ..
- the motor 100 of the first embodiment described above has high motor efficiency due to the improvement of the winding density of the coil 3, the operating efficiency of the air conditioner 500 can be improved.
- the motors of the second and third embodiments may be used instead of the motor 100 of the first embodiment. Further, here, the motor 100 is used as the drive source of the outdoor blower 510 and the drive source of the indoor blower 520, but the motor 100 may be used as at least one of the drive sources.
- the motor 100 of each embodiment can be mounted on an electric device other than the blower of the air conditioner.
- stator 1, 2A, 2B insulator, 3 coil, 4 mold stator, 5 rotor, 6 resin part, 7 shaft, 10 stator core, 10A connection core, 11 yoke, 12 teeth, 13 slot, 21 winding part, 21a 1st End, 21b second end, 21c side, 22 inner side wall, 22a first wall, 22b second wall, 22c side wall, 23 outer wall, 23a first wall, 23b 2nd wall part, 23c side wall part, 30 molding mold, 31 upper mold, 32 lower mold, 33 cavity, 40 mold resin part, 41 opening, 42 bearing support part, 43 circuit board, 44 magnetic sensor , 50 rotor core, 51 magnet insertion hole, 55 magnet, 56 sensor magnet, 80 molding mold, 81 upper mold, 82 lower mold, 83 cavity, 100 motor, 211 curved surface, 212 curved surface, 311 spool, 312 runner, 313 Gate, 315 cylinder, 500 air conditioner, 501 outdoor unit, 502 indoor unit, 503 refrigerant pipe, 504 compressor, 50
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Abstract
Description
<モータ100の構成>
図1は、本発明の実施の形態1におけるモータ100を示す縦断面図である。モータ100は、例えば空気調和装置の送風機に用いられ、インバータで駆動されるブラシレスDCモータである。また、モータ100は、ロータ5にマグネット55が埋め込まれたIPM(Interior Permanent Magnet)モータである。
図2は、モータ100のモールド樹脂部40(図1)を除く部分を示す断面図である。ロータ5は、回転軸であるシャフト7と、シャフト7に対して径方向外側に距離を開けて設けられたロータコア50と、ロータコア50に埋め込まれた複数のマグネット55と、シャフト7とロータコア50との間に設けられた樹脂部6とを有する。
モールドステータ4は、上記の通り、ステータ1とモールド樹脂部40とを有する。モールド樹脂部40は、BMC(バルクモールディングコンパウンド)等の熱硬化性樹脂で形成される。モールド樹脂部40は、負荷側に開口部41を有し、反負荷側に軸受支持部42を有する。ロータ5は、開口部41からモールドステータ4の内部の中空部分に挿入される。
図3および図4は、ステータコア10とインシュレータ2とを示す斜視図および上面図である。インシュレータ2は、絶縁性の樹脂、例えば、PBT(ポリブチレンテレフタレート)、PPS(ポリフェニレンサルファイド)、LCP(液晶ポリマー)、PET(ポリエチレンテレフタレート)等の熱可塑性樹脂で形成される。インシュレータ2は、樹脂をステータコア10と一体成形するか、あるいは樹脂の成形体をステータコア10に組み付けることによって形成される。
次に、モータ100の製造工程について説明する。図7は、インシュレータ2を成形するための成形金型30を示す図である。成形金型30は、可動金型である上金型31と、固定金型である下金型32とを有し、両者の間にキャビティ33が形成される。
コイル3の抵抗Rは、コイル3の抵抗率ρと長さLと断面積Sとを用いて、ρ×L/Sで表される。すなわち、コイル3の抵抗Rは、コイル3の長さLに比例して増加する。そのため、ティース12に巻かれるコイル3の一周当たりの長さ(以下、巻き長と称する)が短いほど、抵抗Rが小さくなる。抵抗Rが小さいほど、モータ損失の一つである銅損が減少し、モータ効率が向上する。コイル3の巻き長を短くする上では、コイル3が巻き付けられるインシュレータ2の巻き付け部21の厚さを薄くすることが有効である。
以上説明したように、実施の形態1では、インシュレータ2の巻き付け部21が、ティース12の周方向の一方の側に位置する第1の端部21aと、他方の側に位置する第2の端部21bと、ティース12の周方向の一方の側に位置する側部21cとを有する。第1の端部21aの軸方向の最大厚さT1と、第2の端部21bの軸方向の最大厚さT2と、側部21cの周方向の最大厚さT3とは、T3<T1<T2を満足する。また、インシュレータ2は、軸方向において第1の端部21aと同じ側に、ゲート痕Gを有する。そのため、インシュレータ2の厚さを効果的に薄くすることができ、その結果、コイル3の巻き付け密度を向上し、モータ効率を向上することができる。
次に、実施の形態2について説明する。図15は、実施の形態2におけるティース12と、インシュレータ2Aの巻き付け部21と、コイル3とを示す断面図である。インシュレータ2Aの巻き付け部21は、実施の形態1と同様、第1の端部21aと、第2の端部21bと、側部21cとを有する。
次に、実施の形態3について説明する。図16(A)は、実施の形態3におけるティース12と、インシュレータ2Bの巻き付け部21と、コイル3とを示す断面図である。インシュレータ2Bの巻き付け部21は、実施の形態1と同様、第1の端部21aと、第2の端部21bと、側部21cとを有する。
次に、上述した各実施の形態のモータが適用可能な空気調和装置について説明する。図17(A)は、実施の形態1のモータ100を適用した空気調和装置500の構成を示す図である。空気調和装置500は、室外機501と、室内機502と、これらを接続する冷媒配管503とを備える。
Claims (13)
- 軸線を中心とする周方向に延在するヨークと、前記ヨークから軸線に向かって延在するティースとを有するステータコアと、
前記ティースを囲む巻き付け部を有するインシュレータと、
前記インシュレータの前記巻き付け部に巻き付けられたコイルと
を有し、
前記インシュレータの前記巻き付け部は、前記軸線の方向において前記ティースの一方の側に位置する第1の端部と、前記ティースの他方の側に位置する第2の端部と、前記周方向において前記ティースの一方の側に位置する側部とを有し、
前記第1の端部は、前記軸線の方向に最大厚さT1を有し、
前記第2の端部は、前記軸線の方向に最大厚さT2を有し、
前記側部は、前記周方向に最大厚さT3を有し、
前記最大厚さT1,T2,T3が、T3<T1<T2を満足し、
前記インシュレータは、前記軸線の方向において前記第1の端部と同じ側に、ゲート痕を有する
ステータ。 - 軸線を中心とする周方向に延在するヨークと、前記ヨークから軸線に向かって延在するティースとを有するステータコアと、
前記ティースを囲む巻き付け部を有するインシュレータと、
前記インシュレータの前記巻き付け部に巻き付けられたコイルと
を有し、
前記インシュレータの前記巻き付け部は、前記軸線の方向において前記ティースの一方の側に位置する第1の端部と、前記ティースの他方の側に位置する第2の端部と、前記周方向において前記ティースの一方の側に位置する側部とを有し、
前記第1の端部は、前記軸線の方向に最大厚さT1を有し、前記第2の端部は、前記軸線の方向に最大厚さT2を有し、
前記第1の端部は、前記ティースとは反対側に凸となる曲率半径RT1の曲面を有し、前記第2の端部は、前記ティースとは反対側に凸となる曲率半径RT2の曲面を有し、
前記最大厚さT1,T2,T3が、T1<T2を満足し、
前記曲率半径RT1,RT2が、RT1>RT2を満足し、
前記インシュレータは、前記軸線の方向において前記第1の端部と同じ側に、ゲート痕を有する
ステータ。 - 前記側部は、前記周方向に最大厚さT3を有し、
前記最大厚さT1,T2,T3が、T3<T1<T2を満足する
請求項2のステータ。 - 前記インシュレータの前記巻き付け部は、
前記第1の端部と前記側部との間に、曲率半径R1を有する角部を有し、
前記第2の端部と前記側部との間に、曲率半径R2を有する角部を有し、
前記曲率半径R1,R2が、R1<R2を満足する
請求項1から3までの何れか1項に記載のステータ。 - 前記曲率半径R1と前記最大厚さT1とが、R1≦T1を満足する
請求項4に記載のステータ。 - 前記インシュレータは、前記軸線を中心とする径方向において前記ティースの内側端部に位置する内側壁部と、前記径方向において前記ティースの外側端部に位置する外側壁部とを有し、
前記ゲート痕は、前記内側壁部に形成されている
請求項1から5までの何れか1項に記載のステータ。 - 前記インシュレータは、熱可塑性樹脂で形成される
請求項1から6までの何れか1項に記載のステータ。 - 前記ステータを覆うモールド樹脂部をさらに備えた
請求項1から7までの何れか1項に記載のステータ。 - 請求項1から8までの何れか1項に記載のステータと、
前記ステータに囲まれ、前記軸線を中心として回転可能なロータと
を備えたモータ。 - 請求項9に記載のモータと、
前記モータによって回転駆動される羽根車と
を備えた送風機。 - 室外機と、前記室外機に冷媒配管で連結された室内機とを備え、
前記室外機と前記室内機の少なくとも一方は、
請求項10に記載の送風機を有する
空気調和装置。 - 軸線を中心とする周方向に延在するヨークと、前記ヨークから軸線に向かって延在するティースとを有するステータコアを用意する工程と、
成形金型を用いて、前記ティースを囲む巻き付け部を有するインシュレータを形成する工程と、
前記巻き付け部にコイルを巻き付ける工程と
を有し、
前記インシュレータを形成する工程では、前記軸線の方向において前記ティースの一方の側に前記巻き付け部の第1の端部を形成し、前記ティースの他方の側に前記巻き付け部の第2の端部を形成し、前記周方向において前記ティースの一方の側に前記巻き付け部の側部を形成し、
前記第1の端部は、前記軸線の方向に最大厚さT1を有し、
前記第2の端部は、前記軸線の方向に最大厚さT2を有し、
前記側部は、前記周方向に最大厚さT3を有し、
前記最大厚さT1,T2,T3が、T3<T1<T2を満足し、
前記成形金型は、前記軸線の方向において、前記第1の端部を形成する部分と同じ側に、ゲートを有する
ステータの製造方法。 - 軸線を中心とする周方向に延在するヨークと、前記ヨークから軸線に向かって延在するティースとを有するステータコアを用意する工程と、
成形金型を用いて、前記ティースを囲む巻き付け部を有するインシュレータを形成する工程と、
前記巻き付け部にコイルを巻き付ける工程と
を有し、
前記インシュレータを形成する工程では、前記軸線の方向において前記ティースの一方の側に前記巻き付け部の第1の端部を形成し、前記ティースの他方の側に前記巻き付け部の第2の端部を形成し、前記周方向において前記ティースの一方の側に前記巻き付け部の側部を形成し、
前記第1の端部は、前記軸線の方向に最大厚さT1を有し、前記第2の端部は、前記軸線の方向に最大厚さT2を有し、
前記第1の端部は、前記ティースとは反対側に凸となる曲率半径RT1の曲面を有し、前記第2の端部は、前記ティースとは反対側に凸となる曲率半径RT2の曲面を有し、
前記最大厚さT1,T2,T3が、T1<T2を満足し、
前記曲率半径RT1,RT2が、RT1>RT2を満足し、
前記成形金型は、前記軸線の方向において、前記第1の端部を形成する部分と同じ側に、ゲートを有する
ステータの製造方法。
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US17/602,702 US20220166279A1 (en) | 2019-04-25 | 2019-04-25 | Stator, motor, fan, air conditioner, and manufacturing method of stator |
JP2021515403A JP7109658B2 (ja) | 2019-04-25 | 2019-04-25 | ステータ、モータ、送風機、空気調和装置およびステータの製造方法 |
EP19925819.5A EP3961870A4 (en) | 2019-04-25 | 2019-04-25 | STATOR, MOTOR, FAN, AIR CONDITIONER DEVICE AND STATOR MANUFACTURING METHOD |
AU2019442093A AU2019442093B2 (en) | 2019-04-25 | 2019-04-25 | Stator, motor, fan, air conditioner, and manufacturing method of stator |
CN201980095553.0A CN113826308A (zh) | 2019-04-25 | 2019-04-25 | 定子、马达、送风机、空气调节装置及定子的制造方法 |
PCT/JP2019/017596 WO2020217375A1 (ja) | 2019-04-25 | 2019-04-25 | ステータ、モータ、送風機、空気調和装置およびステータの製造方法 |
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CN112840528B (zh) * | 2018-10-23 | 2024-06-21 | 三菱电机株式会社 | 旋转电机的绝缘结构体以及旋转电机的绝缘结构体的制造方法 |
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