WO2022059626A1

WO2022059626A1 - Core portion of rotating electrical machine

Info

Publication number: WO2022059626A1
Application number: PCT/JP2021/033410
Authority: WO
Inventors: 慎太郎馬場; 昇吾手塚
Original assignee: 株式会社三井ハイテック
Priority date: 2020-09-15
Filing date: 2021-09-10
Publication date: 2022-03-24
Also published as: JP2022048726A

Abstract

This core portion of a rotating electrical machine includes, at least, an iron core main body formed by stacking a plurality of block iron cores (12) in which a plurality of thin plates (11a) made from a magnetic metal material are stacked and connected to one another, wherein: the iron core main body is provided with an annular yoke portion and a plurality of tooth portions (11c) projecting from the yoke portion; resin insulating portions joined to each side surface of the yoke portion and the tooth portions (11c) facing slots (13) created between the yoke portion and the adjacent tooth portions (11c) of the iron core main body are provided in the slots (13); and the insulating portions are disposed in such a way as to fill all recessed parts on at least one of the block iron cores (12) and the thin plates (11a) on each side surface of the tooth portions (11c).

Description

Core part of rotary electric machine

This disclosure relates to the core part of the rotary electric machine.

In the stator or rotor of a rotating electric machine such as an electric motor or a generator, a laminated iron core is generally used for the core portion in which the coil is arranged. The coil is arranged by being wound around the teeth portion of the laminated iron core. When the coil is arranged on the iron core formed by punching or the like, the contact between the untreated iron core end face and the coil may damage the insulating coating of the coil. As an example of this countermeasure, as in Patent Document 1, a rotary electric machine in which an insulator such as insulating paper is interposed between a tooth portion of an iron core and a coil arranged in a slot between the teeth portions. The core part is known.

Japanese Patent No. 6277892

In the core of the rotary electric machine shown in Patent Document 1, an insulating paper is provided between the coil and the teeth portion. When manufacturing the core part of such a rotary electric machine, it is necessary to insert the insulating paper into the slot between the teeth parts before the coil is arranged in the teeth part, so that the manufacturing efficiency is improved. There was a problem in.

As the laminated iron core forming the core portion, one formed by laminating a plurality of block cores and spot welding the plurality of block cores may be used. Here, the block iron core is an iron core formed by laminating and connecting a plurality of thin plates made of a magnetic metal material, or an iron core formed by connecting a predetermined number of thin plates made of a magnetic metal material by caulking or the like. be.

When a plurality of block cores are laminated to form a laminated core, it is difficult to completely overlap the parts where the plurality of block cores overlap each other, and a step may occur due to misalignment. When there is a step, when the insulating paper is placed on the portion of the laminated iron core facing the coil such as the teeth portion, a partial gap may occur between the laminated iron core and the insulating paper. If air intervenes in this gap, the heat transfer performance from the coil to the iron core deteriorates, and heat can not be properly dissipated from the coil.

Further, the block iron core may be formed by connecting a plurality of thin plates constituting the block iron core by caulking or the like. Therefore, the strength of the block iron core against the force in the torsional direction was not very high. The torsional strength of the laminated core combined with the block core was also not high. As a result, consideration is required such as preventing an excessive force from being applied to the laminated iron core in the core portion manufacturing process and the post-process such as coil winding, so that there is a problem in improving the manufacturing efficiency.

It is an object of the present disclosure to provide a core portion of a rotary electric machine, which promotes heat transfer from the coil to the core portion side and has improved strength.

The core portion of the rotary electric machine according to the present disclosure is the core portion of the rotary electric machine, which has at least an iron core main body formed by further laminating a plurality of block iron cores formed by laminating and connecting a plurality of thin plates made of a magnetic metal material. The iron core main body includes an annular yoke portion and a plurality of teeth portions protruding from the yoke portions, and faces the slot with respect to a slot generated between the yoke portion of the iron core main body and the adjacent teeth portions. A resin insulating portion to be joined to each side surface of the yoke portion and the tooth portion is provided, and the insulating portion is a concave portion on each side surface of the tooth portion, at least on one of the block iron core and the thin plate. Is arranged so as to fill all of them.

As described above, according to the present disclosure, since each side surface of the tooth portion is provided so as to fill all the concave portions at least in either the block iron core space or the thin plate space, the side surface of the tooth portion and the insulating portion joined to the concave portion are completely filled. There is no gap between and. When the conducting wire forming the coil is inserted into the slot, the heat generated by the conducting wire can be transferred to the iron core body through the insulating part joined to the iron core body, so that the efficiency of heat transfer from the coil to the outside can be improved. It can be improved to promote heat dissipation, suppress the temperature rise of the coil, and stabilize the operation of the rotary electric machine.
Further, by providing the insulating portion with respect to the iron core main body, the outer edge portion of the insulating portion is joined so as to follow the shape of each surface facing the slot of the iron core main body. As a result, the insulating portion particularly penetrates into the concave portion on the side surface of the tooth portion and adheres to each other, so that the connection between the thin plates forming the block core and the block cores forming the core body can be strengthened, so that the twist of the core body can be strengthened. Strength is improved.

It is a top view of the core part which concerns on 1st Embodiment of this disclosure. It is an enlarged view of the main part of the core part which concerns on 1st Embodiment of this disclosure. FIG. 2 is an enlarged cross-sectional view taken along the line AA of FIG. It is an enlarged view of the main part of the iron core body before the insulator arrangement in the core part which concerns on 1st Embodiment of this disclosure. It is explanatory drawing which shows the state before resin injection into the slit at the time of manufacturing a core part which concerns on 1st Embodiment of this disclosure. It is a schematic explanatory drawing which shows the mounting state of the iron core body to the mold apparatus at the time of manufacturing a core part which concerns on 1st Embodiment of this disclosure. It is explanatory drawing which shows the arrangement state of another insulator in the core part which concerns on 1st Embodiment of this disclosure. It is a cross-sectional enlarged view of the main part of the iron core body in the core part which concerns on the 2nd Embodiment of this disclosure. It is a cross-sectional enlarged view of the main part of the core part which concerns on the 2nd Embodiment of this disclosure.

(First Embodiment of the present disclosure)
Hereinafter, the core portion of the rotary electric machine according to the first embodiment of the present disclosure will be described with reference to FIGS. 1 to 6. In this embodiment, an example of a core forming a stator of a motor as a rotary electric machine will be described.

In each figure, the core portion 10 of the rotary electric machine according to the present embodiment is formed by laminating and connecting a plurality of thin plates 11a made of a magnetic metal material and further laminating a plurality of block iron cores 12, and the iron core main body. An insulator 15 made of an insulating resin material, which is provided on each side surface of the iron core main body 11 facing each of the plurality of slots 13 provided in the 11 and forms an insulating portion, is provided.

The rotary electric machine using the core portion 10 according to the present embodiment includes a stator in which a coil is arranged around the core portion 10 in a wound state, and a rotor rotatably arranged inside the stator. Since it is a known configuration including a hollow box-shaped case that covers the stator and the rotor, detailed description thereof will be omitted.

The iron core main body 11 is a laminated iron core formed by laminating a plurality of block cores 12, preferably three or more block cores 12. Each block iron core 12 is formed by laminating a plurality of thin plates 11a made of a magnetic metal material.

The thin plate 11a forming the block iron core 12 is formed by punching from a thin plate material made of electromagnetic steel, an amorphous alloy, or the like.
The laminated thin plates 11a are connected to each other by adhesion with an adhesive. However, the method of connecting the thin plates 11a is not limited to this. For example, the thin plates 11a can be connected to each other by using any one or two or more methods such as fixing with a resin such as a thermosetting resin or a thermoplastic resin, or welding the thin plates to each other.

When forming the iron core main body 11 by laminating a plurality of block iron cores 12, the purpose is to cancel the plate thickness deviation of the thin plate 11a and suppress the variation in the thickness in the stacking direction for each part of the iron core main body 11. The transshipment is performed. The transshipment is performed every time the block iron core 12 formed by laminating a plurality of thin plates 11a is stacked. In the transfer process, the block cores 12 to be overlapped are rotated by a predetermined angle in the circumferential direction with respect to the block cores 12 to be overlapped, so that the block cores 12 are overlapped in a state where the angles of the block cores 12 are deviated from each other. ..
In this way, since the plurality of block iron cores 12 forming the iron core main body 11 are stacked while being transferred for each block iron core 12, the rolling process can be performed more quickly than in the case of performing the rolling in units of the thin plates 11a. Can be done.

When a plurality of block cores 12 are stacked without being transposed to form the core body 11, it is ideal that the block cores 12 overlap each other without misalignment so that the side surfaces of the block cores 12 are flush with each other. However, in reality, it is inevitable that the block iron cores 12 will overlap with each other with a slight deviation. In particular, when the block cores 12 are transposed, it is extremely rare that the end faces of the block cores 12 are completely aligned and overlapped with each other, and it is usually avoided that the block cores 12 are slightly displaced from each other. do not have. For this reason, when the iron core body 11 is formed by laminating a plurality of block cores 12, a step due to misalignment occurs at the boundary portion where the block cores 12 overlap, particularly at the boundary portion of the block core 12 on the side surface of the teeth portion 11c. ..

The iron core main body 11 is configured by connecting the stacked block iron cores 12 to each other by spot welding. However, the means for connecting the block iron cores 12 to each other is not limited to this. For example, the block iron cores 12 can be connected to each other by fixing with a resin such as a thermosetting resin or a thermoplastic resin, or by adhering with an adhesive. In addition, if the laminated state of the block cores 12 can be maintained until the insulator 15 is molded and provided in the teeth portion 11c, the block cores 12 may not be connected to each other.

A plurality of slots 13 for providing a coil composed of a plurality of conducting wires 51 are provided at equal intervals on the inner peripheral portion of the iron core main body 11. Each of the slots 13 leads to a space portion that is a rotor arrangement position in the center of the iron core main body 11. In the iron core body, not all slots need to be provided at equal intervals, and some slots may be provided at different intervals.

The iron core main body 11 includes a yoke portion 11b having an annular shape and a teeth portion 11c protruding inward in the radial direction from the inner circumference of the yoke portion 11b. The slot 13 is formed by the tooth portion 11c protruding inward in the radial direction from the inner circumference of the yoke portion 11b. The shape of the yoke portion 11b and the teeth portion 11c of the core body 11 may be the same over the entire axial direction of the core body 11. On the contrary, the iron core main body 11 may include a portion whose cross-sectional shape changes in the axial direction.

As shown in FIG. 4, the width of the teeth portion 11c is formed so as to decrease inward in the radial direction, except for the tip portion of the teeth portion 11c. On the other hand, the width of the slot 13 hardly changes inward in the radial direction except for the portion corresponding to the tip portion of the tooth portion 11c. In other words, the sides of the two teeth portions 11c forming one slot 13 are substantially parallel to each other.

As described above, each slot 13 is composed of a side surface (inner peripheral surface) of the yoke portion 11b and a side surface of the teeth portion 11c. An insulator 15 made of an insulating resin material is provided on each side surface constituting each slot 13.

The insulator 15 is a solidified resin material having an insulating property, for example, an epoxy-based thermosetting resin. Further, the slot 13 has a space portion 13a forming a part thereof, and the insulator 15 has a shape surrounding the space portion 13a.

The space portion 13a is a portion of the slot 13 that remains without the insulator 15. The space portion 13a is configured so that a plurality of conducting wires 51 forming the coil can be inserted through the space portion 13a. In a state where the conducting wire 51 is inserted through the space portion 13a, the insulator 15 occupies the remaining portion of the slot 13 excluding the space portion 13a in which the conducting wire 51 exists. In other words, the insulator 15 is interposed as an insulator between the conducting wire 51 and the iron core main body 11 (yoke portion 11b and teeth portion 11c).

The insulator 15 is joined to each side surface of the iron core main body 11 facing the slot 13. By the way, as described above, the plurality of block iron cores 12 forming the iron core main body 11 are laminated with deviation, and the ends of the thin plates 11a constituting the block iron core 12 are also unevenly laminated, so that the insulator 15 is used. The side surface of the iron core body 11 to be joined is not a smooth continuous surface.

For example, as shown in FIG. 3, a step is generated at the boundary portion of the block iron core 12 on the side surface of the tooth portion 11c due to misalignment. That is, there are irregularities on the side surface of the slot 13 formed by the plurality of block iron cores 12. Further, since the thin plates 11a forming the block core 12 may also be laminated in a displaced state, the side surface itself of the block core 12 also has irregularities.

On the other hand, the insulator 15 has irregularities (an example of a concave portion) existing on the side surface of the slot 13 formed by the block iron core 12 on each side surface of the yoke portion 11b and the teeth portion 11c, and the block iron core formed by the thin plate 11a. It is arranged so as to fill all the unevenness of 12 (another example of the concave portion). Since the thickness of the insulator 15 is 0.1 mm to 0.5 mm, the deviation of the block iron core 12 is sufficiently large as compared with the deviation of several μm to several tens of μm, and the above concave portion is filled without any problem and a step is formed. Can be resolved.

In this case, the thickness of the insulator 15 is different for each side surface of the block iron core 12. The surface of the insulator 15 joined to the space portion 13a of the slot 13 forms a continuous substantially flat surface that stands upright in the axial direction of the core body regardless of the displacement between the block cores.

Further, the thicknesses of the insulators 15 on the side surfaces of the teeth portion 11c facing each other across the space portion 13a of the slot 13 are different from each other. At this time, the distance between the insulators 15 facing each other across the space 13a, that is, the size of the space 13a of the slot 13 is uniform, and the coils can be evenly arranged without bias.

The relationship between the thickness of the insulator provided joined to the side surface of the block iron core 12 and the width of the space portion 13a will be described in more detail. As shown in FIG. 3, the side surface of the block iron core 12 has a concave portion due to the presence of a step, but the surface of the space portion 13a formed by providing the insulator 15 in the slot 13 is substantially flush with each other. be.

Here, the width of the slot 13 is W _s , and the width of the space portion 13 a is W _c . Further, the thickness of the insulator provided on the left hand side of the slot 13 displayed on the left side in FIG. 3 is t _{1, and the thickness of the insulator corresponding to t 1} _and the insulator facing each other across the slot 13 is t ₂ . .. Similarly, the thickness of the insulator provided on the left hand side of the slot 13 displayed on the right side in FIG. 3 is t _{3, and the thickness of the insulator corresponding to t 3} _and the insulator facing each other across the slot 13 is t ₄ . do.

At this time, the sum of the thicknesses of the opposing insulators 15 is always constant at any place in the slot 13. Specifically, the insulator 15 is provided so as to always satisfy t ₁ + t ₂ = t ₃ + t ₄ = W _s − W _c = (constant). At this time, when W _s is constant in each slot 13, t ₁ + t ₂ = t ₃ + t ₄ is also constant, so that the width W _c of the space portion 13a is also constant.

In addition, the insulator 15 may protrude in the axial direction by a predetermined amount (for example, about 0.2 mm to 3 mm) from one end face or both end faces in the axial direction of the iron core body 11, or may be recessed.

The conducting wire 51 provided in the space portion 13a of the insulator 15 is a metal wire-like body having an insulating film formed on its surface, and functions as a coil by being wound around the teeth portion 11c.

As the conducting wire 51, for example, a flat wire which is a metal rod-shaped body having a rectangular or square cross section having an insulating film formed on its surface may be used. In this case, the conductor 51 functions as a coil by connecting the plurality of conductors 51 after inserting the conductor 51 into the space portion 13a of the insulator 15. As shown in FIG. 2, a plurality of (for example, six) conducting wires 51, which are flat wires, may be inserted into one space portion 13a. As a result, the conducting wire 51 is arranged in the space portion 13a in a state where the surfaces on the adjacent sides of the conducting wire 51 are in contact with each other, so that the space factor in the space portion 13a of the conducting wire 51 becomes large, and a plurality of conductors 51 are arranged. The conducting wire 51 can be aligned in the radial direction of the iron core body 11.
It is desirable that the conducting wire 51 is provided so as to minimize the gap between the conducting wire 51 and the insulator 15. Since the amount of air interposed between the conductor 51 and the insulator 15 is reduced, heat transfer from the coil formed by the conductor 51 to the iron core body 11 can be promoted.

Next, a method of manufacturing the core portion according to the present embodiment will be described.
As a premise, a plurality of thin plates 11a punched out from the thin plate material are laminated in advance by a known manufacturing method by adhesion or the like to form a block iron core 12. Further, it is assumed that the iron core main body 11 in which three or more block iron cores 12 are laminated is obtained by laminating the block iron cores 12 while rolling them.
Then, as described above, it is assumed that a step is generated due to the deviation at the boundary portion of each block core 12 in the obtained iron core main body 11, particularly at the boundary portion of the block core 12 on the side surface of the teeth portion 11c.
Therefore, in the present embodiment, the process of forming and providing the insulator 15 in the slot 13 of the iron core main body 11 will be described. Even if a step of correcting the deviation of the block iron core 12 or the thin plate 11a generated during the transportation of the iron core body is executed by, for example, applying a rod to the iron core body 11 from the outer shape side before the step of forming the insulator 15. good.

The insulator 15 is formed and provided inside the slot 13 by the molding device 30. As shown in FIG. 6, the mold device 30 is configured to be insertable and closable in the upper mold 31 and the lower mold 32 that sandwich the iron core main body 11 from both sides in the axial direction, and the space portion 13a in each slot 13 of the iron core main body 11. A core plate 34, a core base 36 that is provided along the lower mold 32 and is configured to support the core 34, and a cal plate arranged between the upper mold 31 and the iron core body 11. It has 37 and a separation plate 38 arranged between the core base 36 and the iron core body 11. A resin flow path 35 (for example, a runner, a gate hole) for guiding the resin to each slot 13 is formed in the cal plate 37 arranged between the upper mold 31 and the iron core main body 11.

The upper die 31 and the lower die 32 are provided on both sides of the iron core main body 11 arranged at a predetermined position of the mold device 30 in the axial direction. The cal plate 37 is in contact with the upper end surface of the iron core body 11 so as to be pressed by the upper mold 31. Further, the separation plate 38 supported by the lower mold 32 and the core base portion 36 is in contact with the lower end surface of the iron core main body 11. As a result, the axial opening of the iron core main body 11 in the slot 13 can be completely closed except for the arrangement region of the core 34, which will be described later.

The core 34 is inserted into each slot 13 from below through the opening of the separation plate 38 provided on the lower mold 32. The radial opening of the iron core body 11 in the slot 13 is closed at the end of the core 34.

When each slot 13 is closed, the molding process is performed. Specifically, as shown in FIGS. 5 and 6, a space closed by the cal plate 37, the separation plate 38, and the core 34, that is, the iron core main body facing the outer peripheral surface of the core 34 and the slot 13. The resin is injected into the gap between the side surface of the eleven.

The resin is injected by extruding the resin material contained in the resin storage pot (not shown) provided in the molding device 30 from the resin storage pot by pressing with a plunger. The resin material extruded from the resin reservoir pot is press-fitted into the gap between the core 34 and the side surface of the iron core main body 11 through the resin flow path 35. When injecting the resin, the mold device 30 applies a predetermined load to the iron core body 11 in the axial direction and the radial direction, and the space between the iron core body 11 and each part of the mold device in contact with the core body 11 may open and the resin may leak out. Try not to.

The size of the gap between the outer peripheral surface of the core 34 and the side surface of the iron core main body 11 facing the slot 13 is 0.1 mm to 0.5 mm, which corresponds to the thickness of the insulator 15. At this time, the mixture such as the filler contained in the resin is not clogged, the fluidity of the resin can be ensured, and the resin can be spread evenly and reasonably over the entire gap, which is suitable for the distribution of the injected resin. It is a gap.

In the molding apparatus 30 according to the present embodiment, the core 34 is inserted from below into each slot 13 of the iron core main body 11, but the present disclosure is not limited to this example. For example, the core 34 may be inserted into each slot 13 from above. Further, regarding the injection direction of the resin press-fitted by pressing with the plunger, the resin may be injected from either the upper or lower side of the iron core main body 11.

Further, when the thickness of the insulator 15 is different for each block iron core 12, the gate position for resin injection in the molding device 30 may be provided at a position facing the gap portion corresponding to the thick portion of the insulator 15. desirable. In this case, the resin flows from a portion having a wide gap corresponding to the portion where the insulator 15 is provided thickly to a portion having a narrow gap corresponding to the portion where the insulator 15 is provided thinly. Since the resin can reach the place where the gap is narrowed through the place where the gap is wide, problems such as unfilling of the resin are less likely to occur.

Of the surfaces of the cal plate 37 and the separation plate 38 that come into contact with the core body 11, a recess may be formed in a portion corresponding to the core 34 in a direction away from the core body 11. As a result, the formed insulator 15 has a shape protruding from both end faces in the axial direction of the iron core main body 11 or a shape protruding along both end faces in the axial direction of the iron core main body 11.

Particularly in the latter case, the cross-sectional area of the resin flow path can be increased by providing the recesses of the cal plate 37 and the separation plate 38. As a result, the resin can be more effectively reached in the entire gap into which the resin should be injected, including a portion where the resin is difficult to spread, such as near the tip of the tooth portion 11c.

On the contrary, a convex portion may be formed at a portion corresponding to the core 34 on the surfaces of the cal plate 37 and the separation plate 38 that come into contact with the iron core main body 11. As a result, the formed insulator 15 has a shape recessed from both end faces in the axial direction of the iron core main body 11 to the inside of the iron core main body 11.

In this case, as shown in FIG. 7, when the resin material is press-fitted, the convex portion of the cal plate 37 or the like enters the end portion of the space portion 13a of the slot 13 and is closed, so that the insulator 15 is closed by the space portion. It is formed in a state of being housed inside 13a. As a result, it is possible to reduce the leakage of the resin from the end of the space portion 13a along the axial end surface of the iron core main body 11 after the resin material is press-fitted. Since the step of removing excess resin adhering to the end face of the iron core main body 11 can be omitted, workability is improved. It is desirable that the recess of the insulator 15 with respect to the end surface of the iron core body 11 is within the plate thickness of the thin plate 11a. At this time, by joining the insulator 15 to the thin plates 11a, the strength of the connection between the thin plates 11a can be increased.

By solidifying the injected resin, an insulator 15 joined to both side surfaces of the teeth portion 11c and the inner peripheral surface of the yoke portion 11b is formed. The core portion 10 is completed by providing the insulator 15 in each slot 13 of the iron core main body 11.

Then, the core portion 10 is released by the molding device 30 separating the upper mold 31, the cal plate 37, the core 34, the lower mold 32, and the separation plate 38 from the iron core main body 11 with respect to the core portion 10. .. After being taken out from the molding device 30, the core portion 10 is supplied to a process such as coil arrangement. In steps such as coil arrangement, the conducting wire 51 is inserted into each slot 13 of the core portion 10. In other words, the conducting wire 51 is inserted into the space portion 13a of the slot 13 so as to be surrounded by the insulator 15.

The frictional force of the core portion 10 with respect to the conducting wire 51 of the insulator 15 is smaller than the frictional force of the insulating paper provided in the core portion with respect to the conducting wire 51 as in Patent Document 1. Therefore, when the conductor 51 is inserted into the slot 13, the conductor 51 is less likely to receive resistance even if it comes into contact with the insulator 15, and the conductor 51 can be smoothly inserted.

The conducting wires 51 inserted into each slot 13 of the core portion 10 are electrically connected to each other by connecting the conducting wires 51 inserted into the slots 13 inserted in several (or adjacent to each other in the circumferential direction) slots 13 in the circumferential direction. It is connected to form a coil. Finally, the core portion and the coil are in a state where they can be used as a stator of a rotary electric machine by wiring windings or attaching them to a case.

The insulator 15 is provided by the molding device 30. The thickness of the insulator 15 is 0.1 mm to 0.5 mm. Since the thickness of the insulator 15 is thinner than that of the insulating paper used for the insulation between the conventional coil and the core, the conductor 51 is less likely to be caught by the insulator 15 when the conductor 51 is inserted into the space 13a of the slot 13. As a result, the lead wire 51 can be smoothly inserted.
Further, since the ratio of the insulating portion (insulator 15) to each slot 13 can be reduced as compared with the case where the insulating paper is used, the space portion 13a becomes wider. In other words, since the area where the conductor 51 can be provided becomes larger, the occupancy rate of the coil (conductor) in the slot 13 becomes higher. Therefore, since a larger amount of current can be passed through the coil, the output of the rotary electric machine can be improved.

Further, by providing the insulator 15 on the iron core main body 11, the connecting strength of the iron core main body 11 is improved. If it is possible to maintain the laminated state of the thin plates 11a and the block iron cores 12 until the process in which the insulator 15 is provided, the thin plates 11a are connected to each other by adhesion or caulking, or the block iron cores 12 are connected to each other by welding or the like. The step may be omitted. After the insulator 15 is provided, it becomes easier to maintain the connection between the thin plates 11a and the block iron cores 12, so that a state in which the thin plates 11a can be used as the iron core main body 11 can be ensured. As described above, when the steps related to the connection between the thin plates 11a and the connection between the block iron cores 12 before the insulator 15 is arranged are not performed, the manufacturing efficiency can be improved and the manufacturing cost can be suppressed.

Subsequently, the heat transfer state from the coil to the core portion in the rotary electric machine to which the core portion according to the present embodiment is applied will be described.
When the rotary electric machine is operated and a current flows through the conducting wire 51, heat is generated in the conducting wire 51. The heat generated in the conductor 51 is mainly via the insulator 15 because the heat conductivity in the insulator 15 interposed between the conductor 51 and the iron core body 11 is superior to the heat conductivity in the air around the coil. It is transmitted to 11.

That is, the heat generated in the coil is transmitted from the conducting wire 51 of the portion of the coil contained in the space 13a of the slot 13 to the insulator 15 in close contact with the surface thereof, and further from the insulator 15 to the iron core main body 11 in close contact with the insulator 15. It is transmitted to the case where the iron core main body 11 is housed.

The insulator 15 which is an insulating portion is provided so as to closely cover each side surface of the iron core main body 11 facing the slot 13. The thickness of the insulator 15 is adjusted for each side surface of each block iron core 12 so that the shape of the surface of the insulator 15 facing the space portion 13a stands up in the axial direction of the iron core body 11 and becomes a continuous substantially flat surface. Therefore, the straightness of the surface can be ensured without being affected by the step due to the displacement between the block iron cores 12 on the side surface of the teeth portion 11c of the iron core main body 11 and the unevenness between the thin plate ends.

Therefore, when the conductor 51 is inserted into the slot 13, for example, the surface of the conductor 51 and the surface of the insulator 15 are almost parallel to each other, so that there is a gap between the conductor 51 and the insulator 15 due to unevenness or inclination of the surface of the insulator 15. Is unlikely to occur. As a result, the amount of air interposed between the conductor 51 and the insulator 15 can be reduced, so that the heat transfer efficiency between the conductor 51 and the iron core main body 11 via the insulator 15 can be improved.

Further, the insulator 15 is provided so as to fill all the unevenness (concave portion) existing on the side surface of the slot 13 formed by the block iron core 12 or the thin plate 11a on each side surface of the tooth portion 11c. As a result, each side surface of the tooth portion 11c and the insulator 15 are in close contact with each other without any gap. For example, when the thin plate 11a is formed by punching, burrs and sagging may remain at the end of the thin plate 11a. At this time, when the thin plates 11a are laminated, a small concave portion may be formed on the side surface of the slot 13 formed by the thin plates 11a. In the present embodiment, the insulator 15 is provided without a gap even in such a concave portion.

This makes it difficult for air to exist between the insulator 15 and the side surface of the teeth portion 11c. In the state where the conducting wire 51 forming the coil is inserted into the slot 13, the heat generated in the conducting wire 51 is transferred to the iron core main body 11 via the insulator 15 provided in the iron core main body 11. At this time, since air is unlikely to exist between the insulator 15 and the side surface of the teeth portion 11c, the efficiency of heat transfer from the coil to the outside can be improved and heat dissipation can be promoted.

By providing the insulator 15 in the molding device 30, the insulator 15 can be formed with high accuracy. Since the dimensional error of the insulator 15 can be reduced, it is not necessary to set a large clearance for insertion around the space portion 13a in which the conducting wire 51 enters. That is, since the clearance between the conductor 51 inserted into the space 13a and the insulator 15 can be reduced, the layer of air interposed between the conductor 51 and the iron core body 11 becomes thinner. As a result, the heat transfer efficiency between the conducting wire 51 and the iron core main body 11 can be improved.

As described above, in the core portion 10 of the rotary electric machine according to the present embodiment, the insulator 15 is provided so as to fill the unevenness (concave portion) existing on the side surface of the slot 13 formed by the block iron core 12 or the thin plate 11a. There is. Since there is no gap between the side surface of the teeth portion 11c and the insulator 15, air that hinders heat transfer between the conducting wire 51 forming the coil and the iron core body 11 exists between the side surface of the teeth portion 11c and the insulator 15. Hateful. This makes it possible to provide the core portion 10 of the rotary electric machine in which the heat transfer efficiency from the coil to the core portion 10 side is promoted.

Further, since the insulator 15 is provided for the teeth portion 11c of the iron core main body 11, the insulator 15 assists the connection between the block iron cores 12 constituting the teeth portion 11c and the thin plates 11a. .. That is, since the connection between the block iron cores 12 and the thin plates 11a is strengthened, the torsional strength of the iron core main body 11 is improved, and therefore, the core portion 10 of the rotary electric machine with improved strength can be provided.

In the core portion 10 of the rotary electric machine according to the present embodiment, the circumferential thickness of the insulator 15 which is an insulating portion provided in one teeth portion 11c is set to t1, and the circumferential direction of the insulator 15 provided in the other teeth portion 11c. When the thickness is t2, t1 + t2 is constant. As a result, the total thickness of the insulators in each slot 13 becomes constant, so that the heat transfer performance from the coil to the iron core main body 11 in each slot 13 can be made constant.

In the core portion 10 of the rotary electric machine according to the present embodiment, the circumferential thickness t1 of the insulator 15 may be different from the circumferential thickness t2 of the insulator 15. If t1 + t2 are constant, the heat transfer performance from the coil in each slot 13 to the iron core main body 11 can be constant.

Note that the rotary electric machine to which the core portion according to the embodiment is applied is an electric machine, but the electric machine is not limited to this, and the rotary electric machine may be a generator. Further, the core portion according to the embodiment is a part of the stator in the inner rotor structure, but is not limited to this, and may be applied as a part of the stator in the outer rotor structure. In addition, the core portion may be used not only as a stator but also as a core of a winding type rotor.

Further, in the core portion of the rotary electric machine according to the embodiment, the insulator 15 on the side surface of the teeth portion 11c has a substantially flat surface in which the surface of the insulator 15 facing the space portion 13a in the slot 13 is continuous in the axial direction of the iron core body 11. However, the present disclosure is not limited to the example of the present embodiment. For example, a plurality of grooves continuous in the axial direction of the iron core body 11 may be formed on the surface of the insulator 15 facing the space portion 13a in the slot 13. In this case, since the contact area between the surface of the insulator 15 and the outer peripheral surface of the conductor 51 can be reduced when the conductor is inserted, the frictional resistance associated with the insertion of the conductor 51 can be suppressed. As a result, the conducting wire 51 can be smoothly inserted into the space portion 13a.

Further, in a rotary electric machine using the completed core portion 10, a plurality of grooves provided on the surface of the insulator 15 shall be used as a flow path for a liquid such as a cooling medium to be flowed between the coil (conductor 51) and the insulator 15. Therefore, the liquid can be circulated around the coil to improve the heat dissipation efficiency of the coil.

Further, in order to facilitate the insertion of the conductor 51 into the space portion 13a, the corner portion of the insulator 15 on the side where the conductor 51 is inserted (for example, the upper side) may be chamfered. In the chamfered portion obtained by such chamfering, the conducting wire 51 can be invited, so that the conducting wire 51 can be easily inserted, and the process of inserting the conducting wire into the core portion 10 can be shortened and labor can be saved.

Further, a sewn portion may be provided at a corner portion of the insulator 15 near the base end portion of the tooth portion 11c. By providing the trace portion in this way, it is possible to prevent the corner portion of the conductor 51 from coming into contact with the corner portion of the insulator 15 and causing frictional resistance when the conductor 51 is a flat wire. As a result, the conductor 51 can be smoothly inserted into the space portion 13a, so that the process of inserting the conductor into the core portion 10 can be shortened and labor can be saved.

(Second Embodiment of the present disclosure)
Next, the core portion of the rotary electric machine according to the second embodiment will be described. For convenience of explanation, the description of the member having the same reference number as the member already described in the description of the embodiment will be omitted.
In the core portion of the rotary electric machine according to the second embodiment, as compared with the core portion 10 according to the first embodiment, the thin plate 11a laminated in each block iron core 12 forming the iron core body 11 is the circumference of the iron core body 11. The difference is that they are stacked by shifting them in the direction. At this time, as shown in FIGS. 8 and 9, the side surface of the tooth portion 11c formed by each block iron core 12 and the thin plate 11a is formed as a side surface inclined stepwise with respect to the stacking direction of the thin plate 11a. The insulator 15 may be arranged in close contact with the stepped side surface of the teeth portion 11c of the block iron core 12. When the side surface of the tooth portion 11c of each block core 12 is inclined in a stepped manner in this way, the laminated thin plates 11a in the block core 12 can be connected by caulking.

When the thin plates 11a are connected to each other by caulking in this way, a slight misalignment occurs between the thin plates 11a due to the caulking. When the block iron core 12 is composed of a plurality of thin plates 11a that are crimped to each other, the side surface of the tooth portion 11c becomes stepped due to this positional deviation. However, according to the present embodiment, since the side surface of the stepped teeth portion 11c is covered by the insulator 15, there is no inconvenience as a core portion of rotary electricity.

The insulator 15 is provided on the inclined side surface of the teeth portion 11c formed by each block iron core. Since the area where the side surface of the block core 12 and the insulator 15 are joined is larger than that of the core portion 10 according to the first embodiment, the connection between the block cores 12 is further strengthened. As a result, the strength of the iron core body 11 can be increased. The thickness of the insulator 15 is preferably 0.1 mm to 0.5 mm. In this case, since the cumulative amount of misalignment due to caulking is sufficiently large as compared with the cumulative amount of several μm, the misalignment of the thin plate 11a can be filled.

Further, due to the deviation at the boundary portion of the block iron core 12, a step in the circumferential direction of the iron core main body 11 is generated on the side surface of the tooth portion 11c.

In the core body 11, the angle α formed by the inclined side surface of the tooth portion in one block core and the axial end surface on the block core side of the other block core is an acute angle. Here, the inclined side surface of the teeth portion is a virtual plane obtained by connecting the ridges (corners) of the plurality of thin plates 11a forming the teeth portion. Simply, when a straight ruler is applied to the side surface of the tooth portion, the angle α formed by the straight line of this ruler and the axial end surface of another block core on the block core side is an acute angle. In this case, the insulator 15 molded and arranged along the side surface of the tooth portion 11c is provided by biting into the recess 12a having an acute angle between the block cores 12, so that the area where the insulator 15 and the block core 12 are joined is large. Therefore, the torsional strength of the iron core body 11 is improved.

Further, since the insulator 15 is provided so as to bite into the narrow recess 12a on the side surface of the teeth portion 11c, it is possible to reduce the room for air to intervene between the side surface of the teeth portion 11c and the insulator 15. As a result, heat can be efficiently transferred from the insulator 15 to the teeth portion 11c side.

The iron core body 11 is formed by laminating three or more block iron cores 12. Since the number of laminated thin plates 11a per block core 12 is relatively small, the difference in the total amount of displacement of the thin plates 11a in one block core 12 can be reduced. As a result, the minimum thickness of the insulator 15 required to make the surface of the insulator 15 a continuous substantially flat surface can be reduced.

When connecting the thin plates 11a constituting the block core 12 by caulking, the configuration is not limited to directly crimping the thin plates 11a, and a method of preventing the caulking shape from remaining on the block core 12 is adopted. You may. For example, a caulking block (scrap portion) is provided on the outer peripheral portion or the inner peripheral portion of each thin plate 11a, and the caulking blocks of the thin plates 11a adjacent to each other in the stacking direction are caulked and joined to connect the thin plates 11a and then caulking. A technique such as removing the block from the thin plate 11a may be used.

(Third Embodiment of the present disclosure)
The core portion according to the first embodiment and the second embodiment is subjected to a treatment for removing oil adhering to the surface of the thin plate, a heat treatment for removing strain (internal stress) associated with processing such as punching of the thin plate, and rust prevention. For the purpose, a bluing treatment or the like for forming a film of triiron tetroxide may be performed on the edge of the thin plate or the like.

When the thin plate 11a forming the iron core body 11 is an electromagnetic steel plate, heat treatment (annealing) is performed to restore the crystal grain size near the end of each thin plate until it becomes substantially the same as the crystal grain size of the other parts in order to remove strain. After such a heat treatment on the iron core body 11, an insulator 15 on the iron core body 11 may be provided.

Further, since the insulator 15 is provided at the end of each thin plate 11a constituting the side surface of the slot 13 (the end where the metal surface is newly exposed by the punching process of the electromagnetic steel sheet covered with the insulating film), each of the insulators 15 is provided. The end of the thin plate 11a is covered with the insulator 15. In this case, since the end portion of the thin plate 11a does not come into contact with air, the side surface of the slot 13 is in a state where a rust preventive effect is imparted. As a result, it is possible to reduce the work in the rust prevention treatment step such as brewing for rust prevention after the heat treatment of the iron core main body 11, and the manufacturing cost can be suppressed.

On the other hand, the thin plate 11a forming the iron core main body 11 after the heat treatment is subjected to rust prevention treatment such as bluing, and a rust preventive film such as triiron tetroxide is formed on the edge of the thin plate and the like, and then the insulator 15 is formed. It may be provided.
In this case, since the surface of the end portion of the thin plate 11a on which the insulator 15 is provided does not change in state such as oxidation due to the formation of the rust-preventive film, the insulator 15 and the thin plate 11a can be easily joined.

In other words, the content of this disclosure can be expressed as follows.
(1) A core portion 10 of a rotary electric machine having an iron core body 11 extending in the axial direction, in which a plurality of block iron cores 12 in which a plurality of thin plates 11a made of a magnetic metal material are laminated and connected are laminated. The iron core body 11 includes an annular yoke portion 11b and a plurality of teeth portions 11c protruding from the yoke portions 11b, and a slot 13 is provided between the yoke portions 11b and a pair of adjacent teeth portions 11c. It is formed and is provided with a resin insulating portion that closely covers each side surface of the yoke portion 11b facing the slot 13 and the pair of teeth portions 11c.
If air is present between the slot 13 and the insulating portion, the heat transfer performance may be deteriorated. However, in the core portion 10 of the rotary electric machine according to the present embodiment, a resin insulating portion (insulator 15) is provided so as to closely cover each side surface of the yoke portion 11b facing the slot 13 and the pair of teeth portions 11c. Therefore, the amount of air interposed between each side surface of the yoke portion 11b facing the slot 13 and the pair of teeth portions 11c and the insulating portion can be reduced. This makes it possible to provide the core portion 10 of the rotary electric machine capable of promoting heat transfer from the coil to the core portion 10 side.
Further, since a resin insulating portion is provided so as to closely cover each side surface of the yoke portion 11b facing the slot 13 and the pair of teeth portions 11c, the block iron cores 12 constituting the iron core main body 11 and the blocks are provided. The connection between the thin plates 11a constituting the iron core 12 is strengthened. As a result, the torsional strength of the block iron core 12 is improved, and the core portion 10 of the rotary electric machine having increased strength can be provided.

(2) It is preferable that the outer surface of the insulating portion covering the teeth portion 11c is flat.
Usually, the side surface of the block iron core 12 formed by laminating the thin plates 11a and the side surface of the iron core main body 11 formed by laminating the block iron core 12 have irregularities due to an error during laminating. Since the outer surface of the insulating portion covering the teeth portion 11c of the rotary electric machine according to the present embodiment is flat, the conducting wire 51 constituting the coil can be smoothly inserted along the insulating portion.

(3) The iron core main body 11 is preferably formed by rolling a plurality of block iron cores 12.
Since the core body 11 is formed by rolling a plurality of block cores 12, the block core 12 can be formed by offsetting the dimensional error of the block core 12. It should be noted that when the rolling is performed, unevenness is more likely to occur, but the insulating portion is provided so as to fill the unevenness on the side surface of the block iron core 12 and the side surface of the iron core body 11, and is provided along the axial direction of the iron core body 11. When the surface is flat, the conductor 51 can be smoothly inserted along the insulating portion.

(4) It is preferable that the block iron core 12 is laminated with a plurality of thin plates 11a displaced from each other in the circumferential direction of the iron core main body 11, and the plurality of thin plates 11a form the side surface of the teeth portion 11c inclined in a stepped manner.
Since the plurality of thin plates 11a form the side surface of the tooth portion 11c inclined in a stepped manner, the insulating portion is provided on the side surface inclined in a stepped manner. By the way, since the thin plates 11a are laminated so as to be offset in the circumferential direction of the iron core main body 11, the area where the stepped side surface and the insulating portion are joined increases. As a result, the torsional strength of the iron core body 11 is further improved.

(5) In the iron core main body 11, one block iron core 12 is laminated with the other block iron core 12 shifted in the circumferential direction of the iron core main body 11, and the stairs of the teeth portion 11c formed by the one block iron core 12 are formed. It is preferable that the angle formed by the side surface inclined in the shape and the end surface of the other block iron core 12 is an acute angle.
Since the angle formed by the stepped side surface of the tooth portion 11c formed by one block core 12 and the end surface of the other block core 12 is an acute angle, an insulating portion is also provided at the acute angle portion. , The joint area between the block iron cores 12 becomes wider. As a result, the connection between the block cores 12 is strengthened, so that the torsional strength of the core body 11 is further improved.

(6) The iron core main body 11 is preferably formed by laminating at least three or more block iron cores 12.
As the number of block iron cores 12 constituting the iron core main body 11 increases, the number of thin plates 11a constituting the block iron core 12 decreases. As a result, the difference in the total amount of unevenness existing in one block core 12 can be made as uniform as possible, so that the insulating portion provided for each uneven block core 12 for each block core 12 can be thinned. This makes it possible to easily insert the conducting wire 51 while suppressing the manufacturing cost for providing the insulating portion.

(7) The thickness of the insulating portion is preferably 0.1 mm to 0.5 mm.
Since the insulating portion is sufficiently thicker than the unevenness generated on the block iron core 12, the insulating portion can sufficiently cover each side surface of the yoke portion 11b facing the slot 13 and the pair of teeth portions 11c.

(8) For each block iron core 12 forming a pair of teeth portions 11c constituting one slot 13, the circumferential thickness of the insulating portion provided in one teeth portion 11c is t1, and the other teeth portion 11c is provided. It is desirable that t1 + t2 is constant when the circumferential thickness of the insulated portion is t2.
In this case, since the total thickness of the insulating portions is constant in any slot 13, the heat transfer performance from the coil to the iron core main body 11 in each slot 13 can be made constant.

(9) In the core portion 10 of the rotary electric machine according to (8), the circumferential thickness t1 of the insulating portion may be different from the circumferential thickness t2 of the insulating portion.
Even if the circumferential thickness t1 of the insulating portion and the circumferential thickness t2 of the insulating portion are different, if t1 + t2 is constant, the heat transfer performance from the coil to the iron core main body 11 can be made constant.

(10) The method for manufacturing the core portion 10 of the rotary electric machine according to any one of (1) to (9) is to stack a plurality of block iron cores 12 to form an iron core main body 11 and to form a thin plate 11a. The iron core body 11 is heat-treated so that the crystal grain size is uniform, and after the heat treatment, the insulating portion covers each side surface of the yoke portion 11b facing the slot 13 and the pair of teeth portions 11c. May include the provision of.
According to the above method, it is possible to achieve improvement of heat transfer performance and improvement of strength of the core portion 10 by removing internal stress and forming an insulating portion.

This disclosure appropriately incorporates the contents disclosed in the Japanese patent application (Japanese Patent Application No. 2020-154710) filed on September 15, 2020.

10 Core part 11 Iron core body 11a Thin plate

11b York part

11c Teeth part 12 Block iron core 12a Recessed part 13 Slot 13a Space part 15 Insulator 30 Molding device 31 Upper type 32 Lower type 34 Core 35 Resin flow path 36 Core base 37 Cal plate 38 Separation plate 51 Lead wire

Claims

In the core portion of a rotary electric machine having at least an iron core body formed by further laminating and connecting a plurality of thin plates made of a magnetic metal material and connecting them.
The iron core body includes an annular yoke portion and a plurality of teeth portions protruding from the yoke portion.
For the slot generated between the yoke portion of the iron core body and the adjacent teeth portion, a resin insulating portion to be joined to each side surface of the yoke portion facing the slot and the teeth portion is provided.
The insulating portion is arranged so as to fill all the concave portions on at least one of the block iron core and the thin plate on each side surface of the tooth portion.
The core of the rotary electric machine.
The outer surface of the insulating portion that covers the teeth portion is flat.
The core portion of the rotary electric machine according to claim 1.
In the iron core body, a plurality of the block iron cores are transposed.
The core portion of the rotary electric machine according to claim 1 or 2.
In the block iron core, a plurality of the thin plates are laminated so as to be displaced from each other in the circumferential direction of the core body, and the plurality of the thin plates form a side surface of the teeth portion inclined in a stepped manner.
The core portion of the rotary electric machine according to any one of claims 1 to 3.
In the core body, one block core is laminated so as to be offset in the circumferential direction of the core body with respect to the other block core.
The angle formed by the stepped side surface of the tooth portion formed by the one block core and the end surface of the other block core is an acute angle.
The core portion of the rotary electric machine according to claim 4.
At least three or more of the block iron cores are laminated on the iron core body.
The core portion of the rotary electric machine according to any one of claims 1 to 5.
The thickness of the insulating portion is 0.1 mm to 0.5 mm.
The core portion of the rotary electric machine according to any one of claims 1 to 6.
For each of the block iron cores forming the pair of teeth portions constituting one slot,
The circumferential thickness of the insulating portion provided on one of the teeth portions is t1.
When the circumferential thickness of the insulating portion provided on the other teeth portion is t2,
t1 + t2 is constant,
The core portion of the rotary electric machine according to claim 7.
The circumferential thickness t1 of the insulating portion is different from the circumferential thickness t2 of the insulating portion.
The core portion of the rotary electric machine according to claim 8.
The method for manufacturing a core portion of a rotary electric machine according to any one of claims 1 to 9.
By stacking a plurality of the block iron cores to form the iron core body,
The iron core body is heat-treated so that the crystal grain size of the thin plate becomes uniform.
After the heat treatment, the insulating portion is provided so as to cover each side surface of the yoke portion facing the slot and the pair of teeth portions.
Manufacturing method of the core part of the rotary electric machine including.