WO2022249828A1 - ステータ及びステータ製造方法 - Google Patents

ステータ及びステータ製造方法 Download PDF

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Publication number
WO2022249828A1
WO2022249828A1 PCT/JP2022/018661 JP2022018661W WO2022249828A1 WO 2022249828 A1 WO2022249828 A1 WO 2022249828A1 JP 2022018661 W JP2022018661 W JP 2022018661W WO 2022249828 A1 WO2022249828 A1 WO 2022249828A1
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WO
WIPO (PCT)
Prior art keywords
yoke
coils
teeth
resin
mold
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2022/018661
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English (en)
French (fr)
Japanese (ja)
Inventor
康司 鎌田
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Panasonic Intellectual Property Management Co Ltd
Original Assignee
Panasonic Intellectual Property Management Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Panasonic Intellectual Property Management Co Ltd filed Critical Panasonic Intellectual Property Management Co Ltd
Priority to US18/560,423 priority Critical patent/US12609575B2/en
Priority to JP2023523367A priority patent/JPWO2022249828A1/ja
Priority to EP22811102.7A priority patent/EP4350955A4/en
Priority to CN202280036231.0A priority patent/CN117356018A/zh
Publication of WO2022249828A1 publication Critical patent/WO2022249828A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • 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
    • 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
    • H02K1/148—Sectional cores
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/10—Applying solid insulation to windings, stators or rotors, e.g. applying insulating tapes
    • H02K15/105—Applying solid insulation to windings, stators or rotors, e.g. applying insulating tapes to the windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/12—Impregnating, moulding insulation, heating or drying of windings, stators, rotors or machines
    • 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
    • H02K3/38—Windings characterised by the shape, form or construction of the insulation around winding heads, equalising connectors, or connections thereto
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K5/00—Casings; Enclosures; Supports
    • H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
    • H02K5/08—Insulating casings
    • 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
    • H02K2203/09—Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations

Definitions

  • the present disclosure relates to a stator and a stator manufacturing method. More particularly, the present disclosure relates to a stator having insulating resin in which a plurality of shaped coils and busbars are molded, and a stator manufacturing method for manufacturing the stator.
  • the armature (stator) described in Patent Document 1 includes a core, a winding coil (formed coil) wound around the core, an insulator disposed between the core and the winding coil to insulate them, and a bus bar connecting the winding coil and an external circuit.
  • the core and busbar are resin-molded with an insulator.
  • the wound coil is wound around the core via an insulator. That is, in Patent Literature 1, the resin for molding the bus bar and the insulator are integrally formed.
  • the winding coils and busbars are not fixed to each other by resin molding. Therefore, when the armature receives vibration from the outside, the winding coils and the busbars may move independently of each other, and the connections between the winding coils and the busbars may break. That is, the reliability of the connecting portion between the winding coil and the bus bar against external vibration is low. For this reason, it is desirable that the winding coil and the bus bar be fixed to each other by resin molding.
  • An object of the present disclosure is to provide a stator and a stator manufacturing method that can improve the reliability of the connection portion between the molded coil and the bus bar against external vibrations and suppress an increase in cost.
  • a stator includes a core, a plurality of molded coils, a busbar, and insulating resin.
  • the core has a cylindrical yoke and a plurality of teeth protruding inward from the yoke from the inner peripheral surface of the yoke.
  • a plurality of formed coils are arranged on a plurality of teeth.
  • the busbar is electrically connected to the plurality of molded coils and is electrically connectable to an external circuit.
  • the insulating resin has insulating properties.
  • the insulating resin includes a first resin portion, a second resin portion, and a third resin portion. The first resin portion molds the bus bar.
  • the second resin portion is arranged between the plurality of teeth and the plurality of molded coils.
  • a third resin portion molds the plurality of molded coils.
  • the first resin portion, the second resin portion and the third resin portion are integrally molded.
  • the first resin portion, the second resin portion and the third resin portion may be made of the same resin material.
  • the insulating resin may not include a boundary surface separating the first resin portion, the second resin portion, and the third resin portion.
  • the core, the plurality of molded coils, the bus bar and the insulating resin may be integrated by insert molding.
  • a stator manufacturing method includes a first step, a second step, a third step, a fourth step, and a fifth step.
  • a tubular yoke and a plurality of teeth to be attached to the inner peripheral surface of the yoke are prepared.
  • a plurality of formed coils and busbars are prepared, and the plurality of formed coils and busbars are positioned and interconnected in a predetermined relative arrangement to assemble a connector.
  • the plurality of teeth are inserted into the plurality of molded coils forming the connection body, and a jig is used to position the relative arrangement between the connection body and the plurality of teeth, and the plurality of teeth are are assembled to the inner peripheral surface of the yoke to assemble an assembly.
  • a molding die is prepared, and the molding die is used in place of the jig while maintaining the relative arrangement of the plurality of molding coils and the plurality of teeth in the assembly.
  • a mold assembly that is assembled to the yoke is assembled.
  • a molten resin is poured into an internal space surrounded by the yoke, the plurality of teeth, and the molding die, and after the molten resin is cured, the Remove the mold.
  • the plurality of teeth are attached to the inner peripheral surface of the yoke and protrude from the inner peripheral surface of the yoke.
  • the plurality of shaped coils are arranged on the plurality of teeth.
  • the bus bar is arranged on one end side of the plurality of shaped coils in the central axis direction of the yoke.
  • the molding die is attached to both sides of the yoke so as to close the openings on both sides of the yoke.
  • the molding die determines the relative position of the plurality of molding coils in the circumferential direction and the relative position of the plurality of molding coils with respect to the yoke, so that the molten metal is formed between the plurality of molding coils and the plurality of teeth. It secures a gap through which the resin flows.
  • a plurality of blocks corresponding to the plurality of formed coils and holding the corresponding formed coils are prepared, and at least one of the plurality of blocks is a portion of the bus bar corresponding to the formed coils. and connecting the plurality of formed coils and the bus bar in a state in which the plurality of formed coils and the bus bar are positioned in a predetermined relative arrangement by the plurality of blocks. You may assemble the said connection body by doing.
  • the jig has a core jig and a holding jig, and the core jig is configured to hold the plurality of teeth in a state in which the plurality of formed coils are inserted.
  • the holding jig is inserted into the central hole of the connecting body and positions the plurality of formed coils in the circumferential direction with respect to the core jig, and the holding jig attaches the plurality of formed coils to the plurality of formed coils. is assembled to one end side of the connection body with the teeth of the inserted, and the relative arrangement of the plurality of formed coils and the plurality of teeth is positioned in the circumferential direction of the core jig.
  • the assembly may be assembled by inserting the plurality of molded coils of the intermediate assembly into the inner peripheral surface of the yoke by inserting them into the central hole of the yoke.
  • the mold has a first mold and a second mold, the first mold has the core jig and the outer mold,
  • the second mold is assembled to the opening on one end side of the yoke, and the outer peripheral mold is placed on the side of the yoke opposite to the second mold.
  • the second mold and the outer mold respectively position the circumferential relative positions of the plurality of formed coils with respect to the yoke and the central axes of the plurality of formed coils with respect to the yoke.
  • the relative position of the directions may be positioned.
  • FIG. 1 is a perspective view of a stator according to an embodiment
  • FIG. FIG. 2 is a partially exploded perspective view of the stator shown in FIG. 2, in which the insulating resin is seen through and portions other than the insulating resin are partially exploded.
  • FIG. 3 is a perspective view of the formed coils of the stator of the same.
  • FIG. 4 is a plan view of the stator shown above, in which the insulating resin is seen through and the portion other than the insulating resin is seen from the upper side (bus bar side).
  • FIG. 5 is a partially enlarged view of the X1-X1 section of FIG. 6 is a partially enlarged view of the X2-X2 section of FIG. 1.
  • FIG. 7 is a flow chart for explaining a method of manufacturing the stator of the above.
  • FIG. 8 is a perspective view of a state in which a plurality of molded coils and busbars are assembled using a jig.
  • 9A is a perspective view of a first block that constitutes the jig of FIG. 8.
  • FIG. 9B is a perspective view of a second block that constitutes the jig of FIG. 8.
  • FIG. FIG. 10 is a perspective view of a connecting body assembled by connecting a plurality of molded coils and bus bars.
  • FIG. 11 is a partially exploded perspective view partially disassembling an assembled body assembled by assembling a core jig, a holding jig, a connector, a plurality of teeth and a yoke.
  • FIG. 12 is an exploded perspective view of the assembled body shown in FIG. 11, in which a core jig, a holding jig, a connector, and a plurality of teeth are disassembled.
  • 13 is a partially enlarged view of the X3-X3 section of FIG. 11.
  • FIG. 14 is a partially enlarged view of the X4-X4 section of FIG. 11.
  • FIG. 15 is a partially enlarged view of the X5-X5 section of FIG. 11.
  • FIG. 16 is a perspective view of an assembly that is assembled by assembling a connector, a plurality of teeth, a yoke, a first mold and a second mold. 17 is an exploded perspective view of the assembly of FIG. 16; FIG. 18 is a partially enlarged view of the X6-X6 section of FIG. 16. FIG. 19 is a partially enlarged view of the X7-X7 section of FIG. 16. FIG. 20 is a partially enlarged view of the X8-X8 section of FIG. 16. FIG.
  • the stator 1 can be used, for example, as a stator for a motor that can be used in a vehicle (eg, automobile). More specifically, the stator 1 forms a motor together with a rotor concentrically and rotatably arranged inside the stator 1 .
  • FIG. 1 is a perspective view of a stator 1 according to an embodiment.
  • FIG. 2 is a partially exploded perspective view in which the insulating resin is seen through and parts other than the insulating resin are partially exploded in the stator 1 of the same.
  • the stator 1 includes a core 2, a plurality of molded coils 3, busbars 4, and insulating resin 5. As shown in FIG.
  • FIG. 5 is a partially enlarged view of the X1-X1 section of FIG.
  • the core 2 is a member forming a magnetic path through which the magnetic flux generated by each of the plurality of molded coils 3 passes.
  • the core 2 is made of metal (for example, ferromagnetic metal such as iron).
  • the core 2 has a yoke (also called O-shaped core) 21 and a plurality of teeth (also called I-shaped core) 22 .
  • the yoke 21 is a portion that supports a plurality of teeth 22.
  • the yoke 21 is cylindrical, for example.
  • Yoke 21 has a circular central hole 21a.
  • the central hole 21a penetrates the yoke 21 in the central axis L1 direction at the center (center C1) of the yoke 21 .
  • the yoke 21 has openings at both ends in the central axis L1 direction.
  • the central axis L1 is the central axis passing through the center C1 of the yoke 21 (see FIG. 4).
  • the yoke 21 has a yoke body 213 and a plurality of (for example, three) connecting portions 214 .
  • the central axis L1 is the central axis of both the yoke 21 and the yoke body 213 .
  • the yoke body 213 is cylindrical with a central hole 21a.
  • the yoke body 213 has openings at both ends of the yoke body 213 in the central axis L1 direction.
  • a plurality of connecting portions 214 are portions that connect with a molding die for forming the insulating resin 5 .
  • the connecting portion 214 is substantially cylindrical.
  • the plurality of connecting portions 214 are provided on the outer peripheral surface of the yoke main body 213 along the direction of the central axis L1, and are arranged on the outer peripheral surface of the yoke main body 213 at equal intervals in the circumferential direction.
  • the connecting portion 214 is provided with a fitting hole 214a penetrating between the upper surface and the lower surface of the connecting portion 214 .
  • a fitting projection of the molding die can be fitted into the fitting hole 214 a formed in the connecting portion 214 .
  • a plurality of (eg, 12) teeth 22 are portions around which a plurality of (eg, 12) formed coils 3 are wound (in other words, arranged).
  • the teeth 22 are provided on the inner peripheral surface of the yoke 21 and protrude inside the yoke 21 from the inner peripheral surface of the yoke 21 .
  • the teeth 22 are substantially T-shaped in a plan view viewed from the direction of the central axis L1. More specifically, each tooth 22 has a tooth body 22p and a pair of projecting portions 22g (see FIG. 5).
  • the tooth main body 22p has a rectangular parallelepiped shape. Teeth main body 22 p protrudes inside yoke 21 from the inner peripheral surface of yoke 21 .
  • the pair of protruding portions 22g protrude on both sides of the yoke 21 in the circumferential direction at the tip end portions of the teeth main bodies 22p.
  • the projecting portion 22g has a triangular shape in plan view.
  • a plurality of teeth 22 are arranged at equal intervals along the circumferential direction of yoke 21 on the inner peripheral surface of yoke 21 .
  • the plurality of teeth 22 are formed from one end of the yoke 21 in the central axis L1 direction to the other end thereof.
  • the yoke 21 and the plurality of teeth 22 are fitted together and assembled. More specifically, a plurality of fitting grooves 211 are provided on the inner peripheral surface of the yoke 21 .
  • the plurality of fitting groove portions 211 correspond to the plurality of teeth 22 on a one-to-one basis, and are portions into which the fitting protrusions 221 (described later) of the corresponding teeth 22 are fitted.
  • the cross-sectional shape of the fitting groove portion 211 is trapezoidal. That is, the lateral width of the fitting groove portion 211 (the width in the circumferential direction of the yoke 21) becomes narrower from the bottom side of the fitting groove portion 211 toward the opening side on the opposite side.
  • the fitting groove portion 211 is provided from one end to the other end of the yoke 21 in the central axis L1 direction. Both ends of the fitting groove 211 in the central axis L1 direction are open at both ends of the yoke 21 in the central axis L1 direction.
  • the plurality of fitting grooves 211 are arranged at equal intervals in the circumferential direction of the yoke 21 on the inner peripheral surface of the yoke 21 .
  • a fitting convex portion 221 is provided on the base end surface of the tooth 22 (that is, the end surface of the tooth 22 on the side opposite to the projecting direction).
  • the fitting protrusion 221 is a portion that fits into the fitting groove 211 of the yoke 21 .
  • the cross-sectional shape of the fitting protrusion 221 is an inverted trapezoid. That is, the lateral width of the fitting protrusion 221 (the width in the circumferential direction of the yoke 21 ) increases from the base end side to the tip end side of the fitting protrusion 221 .
  • the fitting convex portion 221 is provided on the base end surface of the tooth 22 from one end to the other end in the longitudinal direction of the tooth 22 (that is, the central axis L1 direction of the yoke 21).
  • the teeth 22 are assembled to the yoke 21 by fitting the fitting projections 221 of the teeth 22 and the fitting grooves 211 of the yoke 21 .
  • the fitting convex portion 221 of the tooth 22 is inserted into the fitting groove portion 211 along the central axis L1 direction from one end opening of the fitting groove portion 211 of the yoke 21 in the central axis L1 direction (see FIG. 2). Thereby, the fitting convex portion 221 is fitted into the fitting groove portion 211 .
  • FIG. 3 is a perspective view of the formed coil 3 of the stator 1 according to the embodiment.
  • the plurality of molded coils 3 are members that generate magnetic flux when an electric current is supplied from the outside.
  • a plurality of molded coils 3 are wound (that is, arranged) on corresponding teeth 22 of a plurality of teeth 22 of core 2 .
  • the molded coil 3 is a coil obtained by laminating each winding portion while winding an elongated plate-shaped conductor 3c (see FIG. 3).
  • the dimensions of the outer diameter and the inner diameter of the molded coil 3 can be formed with high precision, and the space factor (ratio of the conductor to the cross section of the coil) can be increased.
  • the molded coil 3 is formed in a rectangular frame shape so as to be fittable on the outer periphery of the teeth 22 .
  • both ends 3a and 3b of the molded coil 3 are pulled out of the yoke 21 from the upper end openings of the yoke 21 (that is, the openings on the same side). See Figure 2).
  • One end portion 3 a of both end portions 3 a and 3 b of the formed coil 3 is arranged radially outside the yoke 21 in the formed coil 3 .
  • the other end portion 3b is arranged radially inside the yoke 21 in the formed coil 3 (see FIG. 2).
  • FIG. 4 is a plan view of the stator 1 according to the embodiment, in which the insulating resin is seen through and the portion other than the insulating resin is seen from above (busbar 4 side).
  • the bus bar 4 is a conductor that connects the plurality of molded coils 3 by a predetermined connection method (for example, a star connection method) and functions as wiring for connecting the plurality of molded coils 3 to an external circuit.
  • the busbar 4 is electrically connected to the plurality of molded coils 3 and is a conductor that can be electrically connected to an external circuit.
  • the bus bar 4 connects a plurality of formed coils 3 by, for example, a star connection method. That is, in this embodiment, the stator 1 has, for example, 12 formed coils 3 .
  • the 12 molded coils 3 include four U-phase coils 31U-34U, four V-phase coils 31V-34V, and four W-phase coils 31W-34W.
  • the four U-phase coils 31U, 32U, 33U, and 34U are arranged in this order, for example, every other two in the 12 teeth 22 arranged in a ring.
  • the four V-phase coils 31V, 32V, 33V, and 34V are arranged in this order, for example, every other two in the twelve teeth 22 arranged in a ring.
  • the four W-phase coils 31W, 32W, 33W, and 34W are arranged in this order, for example, every other two in the 12 teeth 22 arranged in a ring.
  • the busbar 4 includes a U-phase busbar 4U, a V-phase busbar 4V, a W-phase busbar 4W, and a neutral point busbar 4K.
  • U-phase bus bar 4U includes a U-phase external terminal 41U and a plurality (eg, three) of U-phase conductor portions 42U to 44U.
  • Each of the U-phase conductor portions 42U to 44U and the neutral point bus bar 4K is a strip-shaped rectangular conductor bent substantially in an arc along the circumferential direction of the yoke 21. As shown in FIG.
  • U-phase conductor portion 42U connects, for example, one end portion 3a of each of U-phase coils 31U and 33U.
  • the U-phase conductor portion 43U connects, for example, the other end portion 3b of the U-phase coil 31U and the one end portion 3a of the U-phase coil 32U.
  • the U-phase conductor portion 44U connects, for example, the other end portion 3b of the U-phase coil 34U and the one end portion 3a of the U-phase coil 33U.
  • Neutral point bus bar 4K for example, connects one end 3b of each of U-phase coils 32U and 34U. That is, the four U-phase coils 31U to 34U are connected in 2-series and 2-parallel by the U-phase bus bar 4U and the neutral point bus bar 4K.
  • the V-phase bus bar 4V includes a V-phase external terminal 41V and a plurality (eg, three) of V-phase conductor portions 42V to 44V.
  • the four V-phase coils 31V to 34V are connected in 2-series and 2-parallel by a V-phase bus bar 4V and a neutral point bus bar 4K.
  • the W-phase bus bar 4W includes a W-phase external terminal 41W and a plurality (eg, three) of W-phase conductor portions 42W to 44W.
  • the four W-phase coils 31W to 34W are connected in 2-series and 2-parallel by a W-phase bus bar 4W and a neutral point bus bar 4K.
  • the three external terminals 41U, 41V, and 41W are arranged at one end in the direction of the central axis L1 of the yoke 21 (that is, the peripheral end) at one place in the circumferential direction of the yoke 21 .
  • the three external terminals 41U, 41V, 41W are arranged in the circumferential direction of the yoke 21 .
  • the three external terminals 41U, 41V, and 41W protrude outward from the yoke 21 from their locations.
  • the busbar 4 is arranged so as to overlap the plurality of molded coils 3 when viewed from the central axis L1 direction of the yoke 21 . More specifically, the busbar 4 can be arranged using at least one of two upper and lower layers (an upper layer and a lower layer) in the central axis L1 direction of the yoke 21 . The lower layer is the layer on the molded coil 3 side, and the upper layer is the layer on the side opposite to the molded coil 3 side.
  • the busbars 4 can be arranged in the radial direction of the yoke 21 using at least one of two inner and outer rows (an outer row and an inner row). That is, the busbars 4 can be arranged within a range of two layers and two rows.
  • the busbar 4 has a two-layer, two-row arrangement structure.
  • busbars 4 may be arranged throughout the same row and layer, may be changed between the upper layer and the lower layer in the middle, or may be changed between the inner row and the outer row.
  • the U-phase conductor portion 42U is arranged from one end 3a of the U-phase coil 31 to one end 3a of the U-phase coil 34U through the upper layer and the outer row.
  • the U-phase conductor portion 43U is arranged from the other end portion 3b of the U-phase coil 31U through the lower layer and the inner row, moving to the lower layer and the outer row on the way to the one end portion 3a of the U-phase coil 32U.
  • FIG. 6 is a partially enlarged view of the X2-X2 section of FIG.
  • the insulating resin 5 is a member for resin-molding the plurality of molded coils 3 and the busbars 4 . More specifically, the insulating resin 5 seals the plurality of molded coils 3 and the busbars 4, and is disposed between the plurality of molded coils 3 and the plurality of teeth 22 (more specifically, between the teeth 22 and the teeth 22). It is a member that insulates between the molded coil 3 that has been formed).
  • the insulating resin 5 is made of a resin having insulating properties.
  • the insulating resin 5 is, for example, a polyphenylene sulfide (PPS) resin containing 30% or more and 50% or less glass fiber.
  • PPS polyphenylene sulfide
  • the fluidity when the insulating resin 5 is injected is good, and the strength after the insulating resin 5 hardens is also preferable. .
  • PBT polybutylene terephthalate
  • unsaturated polyester can also be used as the insulating resin 5 .
  • unsaturated polyester a suitable amount of glass fiber may be added depending on the purpose.
  • Unsaturated polyesters can also be used without the addition of glass fibers.
  • the insulating resin 5 is cylindrical, for example.
  • the insulating resin 5 is provided on the inner peripheral surface of the yoke 21 .
  • the insulating resin 5 covers the entirety of the plurality of molded coils 3, portions of the busbars 4 other than the external terminals 41U, 41V, and 41W, and portions of the plurality of teeth 22 other than the tip surfaces 22s.
  • the insulating resin 5 protrudes in the central axis L1 direction from both ends of the yoke 21 in the central axis L1 direction.
  • the insulating resin 5 includes a first resin portion 51, a second resin portion 52, a third resin portion 53, and a fourth resin portion .
  • the first resin portion 51, the second resin portion 52, the third resin portion 53, and the fourth resin portion 54 are made of the same material (for example, PPS). Note that the fourth resin portion 54 may be omitted.
  • the first resin portion 51 is a portion that molds (that is, seals) the bus bar 4 (see FIG. 6).
  • the first resin portion 51 is, for example, a portion of the insulating resin 5 that is lowered by a certain distance from the one end portion 5a toward the other end portion 5b in the direction of the central axis L1.
  • the second resin portion 52 is a portion interposed between the plurality of teeth 22 and the plurality of molded coils 3 and functioning as an insulator (insulating member) (see FIGS. 5 and 6). That is, the first resin portion 51 is provided on each of the multiple teeth 22 .
  • the first resin portion 51 is a portion arranged between the outer peripheral surface of the tooth 22 and the inner peripheral surface of the molded coil 3 arranged on the tooth 22 .
  • the third resin portion 53 is a portion that molds (that is, seals) the plurality of molded coils 3 (see FIGS. 5 and 6). That is, the third resin portion 53 is a portion that molds the portions other than the inner peripheral surface of each of the molded coils 3 in the plurality of molded coils 3 .
  • the third resin portion 53 includes portions 53 a to 53 e of the insulating resin 5 .
  • the portion 53a is the portion between adjacent formed coils 3 (see FIG. 5).
  • the portion 53b is a portion of the insulating resin 5 that covers the surface of the molded coil 3 on the yoke 21 side (see FIG. 5).
  • the portion 53c is a portion of the insulating resin 5 that covers the surface of the molded coil 3 opposite to the yoke 21 side (see FIG. 5).
  • the portion 53d is a portion between the molded coil 3 and the first resin portion 51 (see FIG. 6).
  • the portion 53e is a portion between the other end portion 5b of the insulating resin 5 (the end face on the side opposite to the busbar 4 side) and the molded coil 3 (see FIG. 6).
  • the fourth resin portion 54 is a portion that covers the base ends of the three external terminals 41U, 41V, and 41W.
  • the fourth resin portion 54 has, for example, a rectangular parallelepiped shape.
  • the fourth resin portion 54 protrudes from the outer peripheral surface of the first resin portion 51 (see FIG. 1).
  • the first resin portion 51, the second resin portion 52, the third resin portion 53 and the fourth resin portion 54 are integrally molded.
  • the insulating resin 5 does not include boundary surfaces dividing the first resin portion 51 , the second resin portion 52 , the third resin portion 53 and the fourth resin portion 54 inside.
  • Such integral molding can be realized, for example, by integrating the core 2, the plurality of molded coils 3, the busbars 4, and the insulating resin 5 by insert molding.
  • FIG. 7 is a flowchart illustrating a manufacturing method of the stator 1 according to the embodiment.
  • the method of manufacturing the stator 1 includes a teeth/yoke preparation step ST1 (first step), a molded coil/bus bar connection step ST2 (second step), and a stator assembly step ST3 (third step). , a mold assembly step ST4 (fourth step), and an insulating resin molding step ST5 (fifth step).
  • the teeth/yoke preparation step ST1 is a step of preparing the yoke 21 and the plurality of teeth 22 used in manufacturing the stator 1 .
  • the formed coil/bus bar connection step ST2 is a step of connecting a plurality of formed coils 3 used in manufacturing the stator 1 and the bus bar 4 to assemble the connection body 6 (see FIG. 10).
  • FIG. 10 is a perspective view of a connecting body assembled by connecting a plurality of molded coils and bus bars.
  • the yoke 21, the plurality of teeth 22, and the connection body 6 are assembled in a predetermined relative arrangement using a jig 10 (see FIG. 11) to form an assembly 110 (see FIG. 11). See) is the process of assembling.
  • FIG. 16 is a perspective view of an assembly assembled by assembling the connector, the plurality of teeth 22, the yoke 21, the first mold and the second mold.
  • the insulating resin molding step ST5 is a step of molding the insulating resin 5 on the inner peripheral surface of the yoke 21 by injecting molten resin into the mold assembly 130 and hardening it.
  • the stator 1 is completed by removing the molding die 70 after molding the insulating resin 5 .
  • Each step ST1 to ST5 will be described in detail below.
  • a plurality of molded coils 3 and busbars 4 are prepared.
  • the plurality of molded coils 3 and bus bars 4 are positioned and interconnected in a predetermined relative arrangement to assemble the connection body 6 (see FIG. 10).
  • the predetermined relative arrangement is the same relative arrangement as the relative arrangement within the stator 1 .
  • FIG. 8 is a perspective view of a state in which a plurality of molded coils and bus bars are assembled using a jig 8.
  • FIG. 9A is a perspective view of a first block 82 that constitutes the jig 8 of FIG. 8.
  • FIG. 9B is a perspective view of the second block 83 that constitutes the jig 8 of FIG. 8.
  • the jig 8 has multiple blocks 81 .
  • the plurality of blocks 81 are made of metal, for example.
  • the plurality of blocks 81 correspond to the plurality of molded coils 3 on a one-to-one basis and hold the corresponding molded coils 3 .
  • At least one block among the plurality of blocks 81 further holds a portion of the busbar 4 that is arranged on the one end side of the corresponding shaped coil 3 . That is, the at least one block 81 positions and holds the corresponding formed coil 3 and the portion of the bus bar 4 arranged above (one end side) of the corresponding formed coil 3 in a predetermined relative arrangement. do.
  • the multiple blocks 81 include multiple first blocks 82 and, for example, one second block 83 .
  • the first block 82 is a block having a busbar positioning portion and is the at least one block described above.
  • the second block 83 is a block that does not have a busbar positioning portion.
  • the first block 82 has a block body 85, a first positioning portion 86, and a second positioning portion 87.
  • the block body 85 is a portion that supports the first positioning portion 86 and the second positioning portion 87 .
  • the block body 85 has, for example, a rectangular plate shape.
  • a cross section of the block body 85 (a cross section perpendicular to the longitudinal direction of the block body 85) is, for example, trapezoidal.
  • the first positioning portion 86 is a portion (formed coil positioning portion) that positions the formed coil 3 by being inserted into the central hole of the formed coil 3 .
  • the first positioning portion 86 has a rectangular parallelepiped shape that can be fitted into the center hole of the molded coil 3 .
  • the first positioning portion 86 is provided on the inner main surface 85a of the block body 85 (for example, the center of the inner main surface 85a). The first positioning portion 86 protrudes from the inner main surface 85a in the direction normal to the inner main surface 85a.
  • the second positioning portion 87 is a portion (busbar positioning portion) that positions the busbar 4 in the section by sandwiching the busbar 4 in the section that overlaps the formed coil 3 positioned by the first positioning section 86 .
  • the second positioning portion 87 is provided on the upper end surface of the block body 85 (for example, the center of the upper end surface).
  • the second positioning portion 87 protrudes from the upper end surface of the block body 85 in the direction normal to the inner main surface 85 a of the block body 85 .
  • the second positioning portion 87 has a support portion 88 and two clamping pieces 89 .
  • the support portion 88 is a portion that supports the two clamping pieces 89 .
  • the support portion 88 is provided on the upper end surface of the block body 85 and protrudes from the upper end surface of the block body 85 in the direction normal to the inner main surface 85 a of the block body 85 .
  • the two clamping pieces 89 protrude from the tip surface of the support portion 88 in the direction normal to the inner main surface 85 a of the block body 85 .
  • the two clamping pieces 89 are arranged on the tip surface of the support portion 88 with a space therebetween in the vertical direction.
  • An upper edge 88 a of the tip surface of the support portion 88 protrudes upward from the upper clamping piece 89 a of the two clamping pieces 89 .
  • the busbars 4 arranged in the lower two rows of the two-layer two-row arrangement structure of the busbars 4 are arranged. That is, the two clamping pieces 89 clamp the two rows of busbars 4 in the lower layer.
  • the busbars 4 arranged in the upper two rows of the two-layer two-row arrangement structure of the busbars 4 are arranged.
  • the tip surface of the support portion 88 has two upper and lower contact surfaces S1 and S2.
  • the upper contact surface S ⁇ b>1 is formed by the upper edge 88 a of the tip surface of the support portion 88 .
  • the upper contact surface S1 contacts the outer side surface of the outermost bus bar 4 among the bus bars 4 arranged on the upper surface of the upper clamping piece 89a.
  • the contact surface S2 on the lower side is formed by the portion between the two clamping pieces 89 of the tip surface of the support portion 88. As shown in FIG.
  • the lower contact surface S2 contacts the outer side surface of the outermost busbar 4 among the busbars 4 arranged between the two clamping pieces 89 .
  • outermost busbar 4" refers to the case where the busbars 4 are arranged in both the outer row and the inner row of the two-layer, two-row arrangement structure, and the case where the busbars 4 are arranged only in the outer row. If so, it is the busbars 4 arranged in the outer row. Further, the above-mentioned “outermost busbar 4" is the busbar 4 arranged in the inner row when the busbar 4 is arranged only in the inner row.
  • the busbar 4 has a plurality of sections that overlap with the plurality of formed coils 3 .
  • the multiple sections are arranged in the circumferential direction of the yoke 21 .
  • the two-layer, two-row arrangement structure of the busbars 4 in each section differs according to each section.
  • a plurality of blocks 81 correspond to a plurality of sections one-to-one.
  • the positions of the two contact surfaces S1 and S2 of the second positioning portion 87 of each first block 82 (positions in the projecting direction of the support portion 88) differ according to the two-layer, two-row arrangement structure of the busbars 4 in the corresponding section. .
  • the second block 83 has a structure in which the second positioning portion 87 is omitted from the first block 82 . That is, the second block 83 has a block body 85 and a first positioning portion 86 .
  • the plurality of blocks 81 are circularly arranged in a predetermined order.
  • the order of arrangement of the plurality of first blocks 81 is the same as the order of arrangement of the plurality of sections of the bus bar 4 in the stator 1 to be manufactured from now on.
  • the plurality of blocks 81 have the molded coils 3 directed inward and adjacent blocks 81 are in contact.
  • the busbars 4 are arranged in the second positioning portions 87 of the plurality of first blocks 82 arranged in an annular shape.
  • the busbars 4 arranged in the lower layer are arranged between the two clamping pieces 89 of the second positioning portion 87 .
  • the outer side surface of the outermost bus bar 4 among the bus bars 4 arranged in the lower layer contacts the lower contact surface S ⁇ b>2 of the second positioning portion 87 .
  • the busbars 4 arranged in the upper layer are arranged on the upper surfaces of the clamping pieces 89 a above the second positioning portion 87 .
  • the outer side surface of the outermost bus bar 4 among the bus bars 4 arranged in the upper layer contacts the upper contact surface S ⁇ b>1 of the second positioning portion 87 .
  • the busbar 4 is positioned and arranged with respect to the jig 8 by being arranged on the second positioning portion 87 of each of the plurality of first blocks 82 as described above.
  • the plurality of forming coils 3 are arranged in the first positioning portion 86 of each of the plurality of blocks 81 so as to be positioned with respect to the jig 8 .
  • the plurality of formed coils 3 and the busbars 4 are positioned and arranged on the jig 8 so as to have a predetermined relative arrangement (the same relative arrangement as in the stator 1).
  • the bus bar 4 is arranged above (one end side) of the plurality of formed coils.
  • both ends 3 a and 3 b of each of the plurality of molded coils 3 are arranged in contact with predetermined portions of the bus bar 4 .
  • connection body 6 is assembled by connecting the plurality of formed coils 3 and the busbars 4 in a predetermined relative arrangement (see FIG. 10). That is, the connector 6 is assembled by connecting the plurality of formed coils 3 and the busbars 4 in a state where the plurality of formed coils 3 and the busbars 4 are positioned in a predetermined relative arrangement by the jig 8 .
  • FIG. 11 is a partially exploded perspective view of an assembly 110 assembled by assembling a core jig, a holding jig, a connecting body 6, a plurality of teeth 22 and a yoke 21. It is a diagram. As shown in FIG. 11, in the stator assembly step ST3 (third step), the assembly 110 is assembled. The assembly 110 inserts a plurality of teeth 22 into the plurality of formed coils 3 of the connection body 6, and uses the jig 10 to position the relative arrangement of the connection body 6 and the plurality of teeth 22, and then forms the plurality of teeth.
  • the assembled body 110 is assembled by assembling a plurality of teeth 22 and yokes 21 prepared in the teeth/yoke preparation step ST1, the connection body 6 assembled in the molded coil/bus bar connection step ST2, and the jig 10. It is That is, the assembly 110 is assembled by assembling components (the yoke 21 , the plurality of teeth 22 , the plurality of molded coils 3 and the busbars 4 ) of the stator 1 other than the insulating resin 5 and the jig 10 . It is The jig 10 is used to position the relative arrangement of the plurality of molded coils 3 of the connection body 6 and the plurality of teeth 22 .
  • FIG. 12 shows an exploded portion of the assembly 110 of FIG. It is an exploded perspective view.
  • the jig 10 includes a core jig 11 and a holding jig 12 .
  • the core jig 11 and the holding jig 12 are made of metal.
  • the core jig 11 determines the relative position of the connector 6 in the circumferential direction with respect to the core jig 11 .
  • the core jig 11 cooperates with the holding jig 12 to position the connection body 6 relative to the core jig 11 in the direction of the central axis L2.
  • the core jig 11 cooperates with the holding jig 12 to position the plurality of teeth 22 relative to the core jig 11 in the direction of the central axis L2.
  • the holding jig 12 positions the plurality of teeth 22 relative to the holding jig 12 in the circumferential direction.
  • a central axis L2 is a central axis that passes through the center C2 of the core jig 11 and the holding jig 12 (see FIG. 12).
  • the core jig 11 includes a cylindrical portion 13, a flange portion 14, a plurality of positioning ribs 15, and a plurality of positioning protrusions 16. and a step portion 17 .
  • the cylindrical portion 13 is a portion arranged in the central hole of the connector 6 . Moreover, the cylindrical portion 13 is a portion arranged in the space inside the plurality of teeth 22 arranged in an annular shape.
  • the flange portion 14 is provided on one peripheral edge of the outer peripheral surface of the cylindrical portion 13 in the direction of the central axis L2.
  • the flange portion 14 protrudes outward from the cylindrical portion 13 .
  • the flange portion 14 is provided with a plurality of through holes (also referred to as gates) for pouring molten resin.
  • the plurality of through holes penetrate through the flange portion 14 in the thickness direction.
  • the plurality of through holes are arranged at intervals along the circumferential direction of the flange portion 14 .
  • the plurality of positioning ribs 15 position the relative positions of the plurality of molded coils 3 of the connection body 6 with respect to the core jig 11 in the circumferential direction (this circumferential direction is the circumferential direction of the yoke 21; the same applies hereinafter).
  • a plurality of positioning ribs 15 are provided on the outer peripheral surface of the cylindrical portion 13 .
  • a plurality of positioning ribs 15 are provided along the central axis L2 direction.
  • a plurality of positioning ribs 15 protrude outward from the cylindrical portion 13 . Upper ends of the plurality of positioning ribs 15 are connected to the lower surface of the flange portion 14 .
  • a plurality of positioning ribs 15 are arranged at equal intervals along the circumferential direction of the cylindrical portion 13 on the outer peripheral surface of the cylindrical portion 13 .
  • the interval between two adjacent positioning ribs 15 is the same length as the circumferential width of the cylindrical portion 13 of the formed coil 3 .
  • 13 is a partially enlarged view of the X3-X3 section of FIG. 11.
  • FIG. 13 A plurality of formed coils 3 of the connection body 6 are arranged to fit between two adjacent positioning ribs 15 on the outer peripheral surface of the cylindrical portion 13 (see FIG. 13). Thereby, the relative positions of the plurality of formed coils 3 in the circumferential direction with respect to the core jig 11 are determined.
  • the plurality of positioning protrusions 16 are portions for positioning the plurality of formed coils 3 of the connection body 6 with respect to the core jig 11 in the direction of the central axis L2.
  • a plurality of positioning protrusions 16 protrude downward from the lower surface of the flange portion 14 by a predetermined length. The lower end of the positioning protrusion 16 contacts the upper end of the formed coil 3, thereby restricting the upward movement of the formed coil 3 (toward the flange portion 14) with respect to the core jig 11 (see FIG. 15).
  • 15 is a partially enlarged view of the X5-X5 section of FIG. 11.
  • the plurality of positioning protrusions 16 ensure a gap between the plurality of molded coils 3 and the flange portion 14 in which the insulating resin 5 is formed.
  • the lower ends of the positioning protrusions 16 are arranged above the lower ends of the positioning ribs 15 .
  • a plurality of positioning protrusions 16 are arranged, for example, one each between two adjacent positioning ribs 15 .
  • the stepped portion 17 is a portion that catches the edge of the upper surface of the plurality of teeth 22 .
  • the edges of the upper surfaces of the teeth 22 are caught by the stepped portions 17 , thereby restricting upward movement of the plurality of teeth 22 with respect to the core jig 11 .
  • the stepped portion 17 has a region above the stepped portion 17 (on the side of the flange portion 14 ) that protrudes further toward the outer periphery of the columnar portion 13 than a region below the stepped portion 17 .
  • the stepped portion 17 is provided below the plurality of positioning ribs 15 on the outer peripheral surface of the cylindrical portion 13 .
  • the step portion 17 is formed over the entire circumference of the cylindrical portion 13 .
  • the holding jig 12 has a substrate portion 24 , a plurality of fixing rods 25 , a plurality of positioning ribs 26 and a plurality of positioning protrusions 27 .
  • the substrate portion 24 has a circular plate shape.
  • the upper surface 24a of the substrate portion 24 has a central portion 24b and a peripheral edge portion 24c.
  • the central portion 24b protrudes upward from the peripheral portion 24c.
  • the central portion 24b has a central upper surface 24d and a central peripheral side surface 24e.
  • a central upper surface 24 d of the central portion 24 b is a portion that contacts the lower surface of the cylindrical portion 13 of the core jig 11 .
  • the central upper surface 24 d is circular and has the same size as the lower surface of the columnar portion 13 .
  • the plurality of fixing rods 25 determine the circumferential relative positions of the plurality of teeth 22 with respect to the holding jig 12 .
  • a plurality of fixed rods 25 sandwich projecting portions 22 g of a plurality of teeth 22 with the outer peripheral surface of cylindrical portion 13 of core jig 11 .
  • a plurality of fixing rods 25 are provided on the outer peripheral edge of the central upper surface 24 d of the substrate portion 24 .
  • a plurality of fixing rods 25 protrude above the substrate portion 24 .
  • a plurality of fixed rods 25 are arranged at equal intervals along the circumferential direction of the central upper surface 24d of the substrate portion 24 on the outer peripheral edge of the central upper surface 24d.
  • FIG. 14 is a partially enlarged view of the X4-X4 section of FIG.
  • a plurality of fixing rods 25 are arranged between adjacent teeth 22 in a plurality of teeth 22 arranged in a ring (see FIG. 14).
  • the fixing rod 25 sandwiches the projecting portions 22 g of the teeth 22 on both sides of the fixing rod 25 with the outer peripheral surface of the cylindrical portion 13 of the core jig 11 .
  • the cross section (the cross section perpendicular to the central axis L2) of the fixing rod 25 is trapezoidal, for example. That is, the fixed rod 25 has both side surfaces corresponding to both oblique sides of the trapezoid and an inner surface corresponding to the upper base (shorter base) of the trapezoid.
  • the fixing rods 25 are arranged so that the inner surfaces of the fixed rods 25 are in contact with the outer peripheral surface of the cylindrical portion 13 of the core jig 11, and the adjacent teeth 22 are held between the side surfaces of the both sides and the outer peripheral surface of the cylindrical portion 13.
  • the projecting portion 22g is sandwiched. Thereby, the plurality of teeth 22 are positioned and fixed in the circumferential direction of the cylindrical portion 13 on the outer peripheral surface of the cylindrical portion 13 of the core jig 11 .
  • the plurality of positioning ribs 26 position the circumferential relative positions of the plurality of formed coils 3 of the connecting body 6 with respect to the holding jig 12 .
  • a plurality of positioning ribs 26 are provided at a reentrant portion between a central peripheral side surface 24 e and a peripheral edge portion 24 c of the substrate portion 24 of the holding jig 12 .
  • the plurality of positioning ribs 26 are rectangular flat plates.
  • the plurality of positioning ribs 26 are arranged at regular intervals in the circumferential direction of the substrate portion 24 .
  • the distance between two adjacent positioning ribs 26 is the same length as the lateral width of the formed coil 3 .
  • a plurality of molded coils 3 of the connecting body 6 are arranged in a fitted manner between two adjacent positioning ribs 26 . This also determines the circumferential relative positions of the plurality of forming coils 3 with respect to the holding jig 12 .
  • the plurality of positioning protrusions 27 position each of the plurality of formed coils 3 of the connection body 6 with respect to the core jig 11 in the direction of the central axis L2.
  • the plurality of positioning protrusions 27 protrude upward from the peripheral edge portion 24c of the substrate portion 24 by a predetermined length.
  • the upper end of the positioning protrusion 27 contacts the lower surface of the formed coil 3 to restrict the downward movement of the formed coil 3 with respect to the core jig 11 (see FIG. 15).
  • Two positioning protrusions 27 are provided between two adjacent positioning ribs 26 on the peripheral edge portion 24 c of the substrate portion 24 .
  • the plurality of positioning protrusions 27 ensure a gap in which the insulating resin 5 is formed between the plurality of molded coils 3 and the peripheral edge portion 24 c of the holding jig 12 .
  • the intermediate assembly 100 includes a plurality of teeth 22 prepared in the teeth/yoke preparation step ST1, the connecting members 6 assembled in the molded coil/bus bar connection step ST2, and jigs 10 (a core jig 11 and a holding jig). 12) are assembled together.
  • a plurality of teeth 22 are inserted into the center holes of each of the plurality of molded coils 3 from the inside of the connector 6. In that case, all of the plurality of teeth 22 cannot be arranged in the respective center holes of the plurality of formed coils 3 at once. Therefore, a plurality of teeth 22 are divided into a plurality of sets, and each set of teeth 22 is inserted into the center hole of the formed coil 3 . In this manner, a plurality of teeth 22 are annularly arranged on the connector 6 .
  • the cylindrical portion 13 of the core jig 11 is inserted into the central hole of the connecting body 6 in which the plurality of teeth 22 are arranged (that is, inside the plurality of teeth 22 arranged in an annular shape).
  • the cylindrical portion 13 of the core jig 11 is inserted into the central hole of the connector 6 until the stepped portion 17 of the core jig 11 contacts the edge of the upper surface of the plurality of teeth 22 . That is, the core jig 11 is inserted into the central hole of the connection body 6 in a state in which the plurality of teeth 22 are inserted into the plurality of formed coils 3 .
  • the cylindrical portion 13 presses the plurality of teeth 22 from the inside of the connecting body 6 to the outside.
  • the fitting protrusions 221 on the base end surfaces of the plurality of teeth 22 protrude from the central holes of the plurality of molded coils 3 to the outer peripheral side of the connecting body 6 .
  • tip end surfaces 22 s of the plurality of teeth 22 are in contact with the outer peripheral surface of the cylindrical portion 13 of the core jig 11 .
  • the plurality of formed coils 3 of the connection body 6 are arranged between the plurality of positioning ribs 15 of the core jig 11 .
  • the core jig 11 positions the plurality of formed coils 3 in the circumferential direction with respect to the core jig 11 . Also, the lower surfaces of the plurality of positioning protrusions 16 of the core jig 11 contact the upper ends of the plurality of formed coils 3 of the connection body 6 .
  • the holding jig 12 is assembled to the lower end side (one end side) of the connection body 6 . That is, the holding jig 12 is attached to one end side of the connection body 6 in a state in which the plurality of teeth 22 are inserted into the plurality of formed coils 3 . More specifically, the plurality of fixing rods 25 of the holding jig 12 are attached to the lower surface of the cylindrical portion 13 of the core jig 11 from the lower side of the connection body 6 so that the central upper surface 24 d of the substrate portion 24 of the holding jig 12 is placed on the lower surface of the cylindrical portion 13 of the core jig 11 .
  • the connector 6 is inserted between the plurality of formed coils 3 (that is, between the plurality of teeth 22) until contact is made.
  • each tooth 22 In this inserted state, the projecting portions 22g on both sides of each tooth 22 are sandwiched between the fixing rods 25 on both sides of the tooth 22 and the outer peripheral surface of the cylindrical portion 13 of the core jig 11. Thereby, the plurality of teeth 22 are fixed on the outer peripheral surface of the cylindrical portion 13 of the core jig 11 by the plurality of fixing rods 25 .
  • the plurality of fixing rods 25 determine the circumferential positions of the plurality of teeth 22 with respect to the core jig 11 .
  • Each of the formed coils 3 of the connecting body 6 is arranged between the positioning ribs 26 of the holding jig 12 .
  • the holding jig 12 positions the plurality of forming coils 3 in the circumferential direction with respect to the core jig 11 .
  • the holding jig 12 positions the relative arrangement of the plurality of formed coils 3 and the plurality of teeth 22 in the circumferential direction of the core jig 11 .
  • the upper ends of the plurality of positioning projections 27 of the holding jig 12 come into contact with the lower ends of the plurality of formed coils 3 of the connector 6 .
  • the intermediate assembly 100 is assembled by positioning and assembling the connection body 6 and the plurality of teeth 22 in a predetermined relative arrangement using the core jig 11 and the holding jig 12 (FIG. 11).
  • the plurality of formed coils 3 of the connector 6 with respect to the core jig 11 are aligned in the circumferential direction ( This circumferential direction is the circumferential direction of the yoke 21.) are positioned (see FIG. 13).
  • the plurality of positioning protrusions 16 of the core jig 11 and the plurality of positioning protrusions 27 of the holding jig 12 allow the relative positions of the plurality of formed coils 3 of the connection body 6 with respect to the core jig 11 in the direction of the central axis L2. positioned (see Figure 15).
  • the plurality of fixing rods 25 of the holding jig 12 determine the circumferential relative positions of the plurality of teeth 22 with respect to the core jig 11 (see FIG. 14).
  • the positions of the plurality of teeth 22 in the central axis L2 direction with respect to the core jig 11 are positioned by the stepped portion 17 of the core jig 11 and the central upper surface 24d of the holding jig 12 (see FIG. 15).
  • the plurality of molded coils 3 and the plurality of teeth 22 are positioned in the same relative arrangement (predetermined relative arrangement) as in the stator 1 .
  • the bus bar 4 is arranged on one end side (upper side) of the plurality of molded coils 3 in the central axis L2 direction of the yoke 21 .
  • this intermediate assembly 100 is inserted into the central hole 21a of the yoke 21 prepared in the tooth/yoke preparation step ST1 (see FIG. 11).
  • the plurality of teeth 22 of the intermediate assembly 100 are assembled to the inner peripheral surfaces of the yokes 21 .
  • the fitting protrusions 221 of the multiple teeth 22 are fitted into the multiple fitting grooves 211 of the inner peripheral surface of the yoke 21 .
  • the plurality of teeth 22 are positioned and fixed to the inner peripheral surface of the yoke 21 .
  • the assembly 110 is assembled.
  • FIG. 17 is an exploded perspective view of the assembly shown in FIG. As shown in FIGS. 16 and 17, in the mold assembly step ST4, the mold assembly 130 is assembled. In the assembly 110 assembled in the stator assembly step ST3 by preparing the molding die 70, the mold assembly 130 is repaired while maintaining the relative arrangement of the plurality of molding coils 3 and the plurality of teeth 22. Instead of the fixture 10, the molding die 70 is assembled to the yoke 21 for assembly.
  • the molding die 70 is composed of a first die 71 and a second die 72 .
  • the first mold 71 is composed of a core mold 73 and a peripheral mold 74 .
  • the core die 73 is also used as the core jig 11 .
  • the molding mold 70 includes a first mold 71 and a second mold 72 .
  • a first mold 71 has an inner peripheral surface of the insulating resin 5 to be formed (see FIG. 1) and an insulating resin 5 , and a mold for forming the portion above the core 2 and the fourth resin portion 54 (see FIG. 1).
  • the first mold 71 is attached to one end of the yoke 21 in the central axis L2 direction.
  • the first mold 71 has a core mold 73 , a peripheral mold 74 and a terminal mold 75 .
  • the center axis L2 is the center axis of each of the core die 73, the outer periphery die 74, and the second die 72. As shown in FIG.
  • the core mold 73 is a mold for molding the inner peripheral surface of the insulating resin 5 to be formed and the inner peripheral half region of the upper surface of the insulating resin 5. is.
  • the core mold 73 is a mold using the core jig 11 .
  • the core die 73 also serves as the core die 73 with the core jig 11 attached to the connection body 6 in the stator assembly step ST3 as it is attached. Therefore, in the core mold 73, the same components as those of the core jig 11 are denoted by the same reference numerals, and detailed description thereof will be omitted.
  • FIG. 20 is a partially enlarged view of the X8-X8 section of FIG. 16.
  • FIG. A plurality of molded coils 3 of the connection body 6 are respectively arranged between a plurality of positioning ribs 15 of the core mold 73 (see FIG. 18).
  • 18 is a partially enlarged view of the X6-X6 section of FIG. 16.
  • the peripheral mold 74 is a mold for molding the outer peripheral half region of the upper surface of the insulating resin 5 to be molded and the outer peripheral surface of the portion of the insulating resin 5 above the core 2 .
  • the outer peripheral die 74 has an annular plate portion 741 , an outer peripheral wall portion 742 , a plurality of positioning ribs 743 , a plurality of positioning protrusions 744 , and a plurality of connecting portions 745 .
  • a circular through hole 741 a is provided in the center of the annular plate portion 741 .
  • the through hole 741a is a portion where the flange portion 14 of the core mold 73 is fitted.
  • the outer peripheral wall portion 742 is cylindrical.
  • the outer peripheral wall portion 742 is provided on the outer peripheral edge of the lower surface of the annular plate portion 741 .
  • the outer peripheral wall portion 742 protrudes downward from the outer peripheral wall portion 742 .
  • the outer peripheral wall portion 742 has a rectangular notch portion 742a.
  • the notch portion 742a is a portion where the terminal mold 75 is arranged.
  • the cutout portion 742a is provided so as to cut out a portion of the lower end of the outer peripheral wall portion 742 in a rectangular shape.
  • the plurality of positioning ribs 743 are portions that position the plurality of forming coils 3 of the connection body 6 relative to the outer peripheral mold 74 in the circumferential direction.
  • a plurality of positioning ribs 743 are provided on the inner peripheral surface of the outer peripheral wall portion 742 .
  • a plurality of positioning ribs 743 protrude inside the outer peripheral wall portion 742 from the inner peripheral surface of the outer peripheral wall portion 742 .
  • a plurality of positioning ribs 743 are provided along the central axis L2 direction of the outer peripheral mold 74 . The upper end of the positioning rib 743 is connected to the lower surface of the annular plate portion 741 .
  • the plurality of positioning ribs 743 are arranged at equal intervals in the circumferential direction of the outer peripheral wall portion 742 on the inner peripheral surface of the outer peripheral wall portion 742 .
  • the interval between two adjacent positioning ribs 743 is the same length as the circumferential width of the outer peripheral mold 74 in the molded coil 3 .
  • a plurality of molded coils 3 of the connection body 6 are arranged in a fitting manner between two adjacent positioning ribs 743 in the outer peripheral mold 74 (see FIG. 18). Thereby, the relative positions of the plurality of forming coils 3 in the circumferential direction with respect to the outer peripheral mold 74 are determined.
  • the plurality of positioning protrusions 744 are portions for positioning the relative positions of the plurality of molded coils 3 of the connection body 6 with respect to the outer peripheral mold 74 in the direction of the central axis L2.
  • a plurality of positioning protrusions 744 protrude downward from the lower surface of the annular plate portion 741 by a predetermined length. The lower end of the positioning protrusion 744 comes into contact with the upper end of the forming coil 3, thereby restricting upward movement of the forming coil 3 with respect to the outer peripheral die 74 (see FIG. 20).
  • the plurality of positioning protrusions 744 secure a gap in which the insulating resin 5 is formed between the plurality of molding coils 3 and the annular plate portion 741 of the outer peripheral mold 74 .
  • the lower ends of the positioning protrusions 744 are arranged above the lower ends of the positioning ribs 743 .
  • the plurality of positioning protrusions 744 are arranged, for example, one each between two adjacent positioning ribs 743 on the lower surface of the annular plate portion 741 .
  • a plurality of (eg, three) connecting portions 745 are portions that connect to a plurality of (eg, three) connecting portions 214 of the yoke 21 .
  • the plurality of connecting portions 745 are substantially cylindrical.
  • the plurality of connecting portions 745 are provided on the outer peripheral surface of the outer peripheral wall portion 742 along the direction of the central axis L2 and are arranged at equal intervals in the circumferential direction of the outer peripheral wall portion 742 .
  • a fitting projection 745 a that fits into the fitting hole 214 a on the upper surface of the coupling portion 214 of the yoke 21 is provided at the lower end of the coupling portion 745 .
  • the yoke 21 and the outer mold 74 are positioned and connected to each other in the circumferential direction of the yoke 21 by fitting the fitting projections 745 a of the outer mold 74 into the fitting holes 214 a on the upper surface of the yoke 21 .
  • the outer peripheral mold 74 is attached to the opening of the upper surface of the yoke 21 of the connection body 6 (that is, the side opposite to the second mold 72 side).
  • the flange portion 14 of the core mold 73 is fitted into the through hole 741 a of the outer mold 74 .
  • the lower end surface of the outer peripheral wall portion 742 of the outer peripheral die 74 is in contact with the upper end surface of the yoke 21 of the connector 6 .
  • the fitting protrusions 745 a of the plurality of connecting portions 745 of the outer peripheral mold 74 are fitted into the fitting holes 214 a on the upper surface of the plurality of connecting portions 214 of the yoke 21 .
  • the lower ends of the plurality of positioning protrusions 744 of the outer peripheral mold 74 are in contact with the upper ends of the plurality of molded coils 3 of the connection body 6 (see FIG. 20).
  • a plurality of forming coils 3 of the connection body 6 are respectively arranged between a plurality of positioning ribs 743 of the outer peripheral mold 74 (see FIG. 18).
  • the tip portions of the three external terminals 41U, 41V, 41W of the busbar 4 of the connector 6 protrude outside the outer peripheral mold 74 through the notch 742a of the outer peripheral mold 74 .
  • the terminal mold 75 is a mold for forming the fourth resin portion 54 .
  • the terminal mold 75 is fitted into the notch 742 a of the outer peripheral mold 74 .
  • the terminal die 75 has a rectangular parallelepiped shape elongated in the horizontal direction.
  • One side surface 75a of the terminal mold 75 is concavely curved along the longitudinal direction of the one side surface 75a.
  • One side surface 75a of the terminal mold 75 is provided with a molding recess 75b.
  • the inner surface of the molding recess 75 b forms the outer peripheral surface of the fourth resin portion 54 .
  • Three holes 75c into which the tips of the three external terminals 41U, 41V, 41W of the connector 6 are inserted are provided in the bottom surface of the molded recess 75b (that is, the inner surface facing the one side surface 75a).
  • This terminal mold 75 is attached to the notch portion 742 a of the outer peripheral wall portion 742 of the outer peripheral mold 74 .
  • one side surface 75a of the terminal mold 75 is fitted into the notch 742a.
  • the terminal mold 75 protrudes outward from the outer peripheral wall portion 742 of the outer peripheral mold 74 .
  • the tip portions of the three external terminals 41U, 41V, 41W of the connector 6 are inserted into the three holes 75c of the terminal mold 75. As shown in FIG.
  • (2-4-1-4) Second Mold As shown in FIGS. 16 and 17, the second mold 72 is placed below the core 2 in the insulating resin 5 (see FIG. 1) to be formed. forming part of The second mold 72 is attached to the opening of the yoke 21 on one end side (the side opposite to the first mold 71 side) in the central axis L2 direction instead of the holding jig 12 .
  • the second mold 72 is, for example, a circular plate.
  • the second mold 72 has a substrate portion 76 , a plurality of positioning ribs 77 , a plurality of positioning protrusions 78 and a plurality of connecting portions 79 .
  • the substrate portion 76 is, for example, a circular plate.
  • An annular groove portion 80 is provided on the upper surface of the substrate portion 76 .
  • the annular groove portion 80 is formed in an annular shape along the outer peripheral edge of the upper surface of the substrate portion 76 .
  • the plurality of positioning ribs 77 are portions that position the plurality of forming coils 3 of the connection body 6 relative to the second mold 72 in the circumferential direction.
  • a plurality of positioning ribs 77 are provided in the annular groove portion 80 at the reentrant corner portion between the bottom surface 80a and the inner peripheral surface 80b and the reentrant corner portion between the bottom surface 80a and the outer peripheral surface 80c.
  • the plurality of positioning ribs 77 are rectangular flat plates.
  • the plurality of positioning ribs 77 are arranged at regular intervals in the circumferential direction of the substrate portion 76 .
  • the interval between two positioning ribs 26 adjacent to each other in the circumferential direction of the substrate portion 76 is the same length as the lateral width of the molded coil 3 .
  • a plurality of formed coils 3 of the connection body 6 are arranged so as to fit between two positioning ribs 77 adjacent to each other in the circumferential direction of the substrate portion 76 . Thereby, the relative positions of the plurality of forming coils 3 in the circumferential direction with respect to the second mold 72 are determined.
  • the plurality of positioning protrusions 78 are portions that position the plurality of forming coils 3 of the connection body 6 with respect to the second mold 72 in the direction of the central axis L2.
  • the plurality of positioning protrusions 78 protrude upward from the bottom surface of the annular groove 80 by a predetermined length.
  • the upper ends of the positioning protrusions 78 contact the lower ends of the forming coils 3 to restrict downward movement of the plurality of forming coils 3 with respect to the second mold 72 (see FIG. 20).
  • the plurality of positioning protrusions 78 ensure a gap between the plurality of molding coils 3 and the second mold 72 in which the insulating resin 5 is formed.
  • two positioning protrusions 78 are arranged between two adjacent positioning ribs 77 at the inner and outer peripheral edges of the annular groove 80 .
  • a plurality of (eg, three) connecting portions 79 are portions that are coupled to a plurality of (eg, three) connecting portions 214 of the yoke 21 .
  • the plurality of connecting portions 79 are substantially cylindrical.
  • a plurality of connecting portions 79 are provided on the outer peripheral surface of the substrate portion 76 along the direction of the central axis L2. Moreover, the plurality of connecting portions 79 are arranged at equal intervals in the circumferential direction on the outer peripheral surface of the substrate portion 76 .
  • a fitting projection 79 a that fits into the fitting hole 214 a of the connecting portion 214 of the yoke 21 is provided at the upper end of the connecting portion 79 .
  • the second mold 72 and the yoke 21 are positioned and connected to each other in the circumferential direction of the yoke 21 by fitting the fitting projections 79a of the second mold 72 into the fitting holes 214a of the yoke 21 .
  • the second mold 72 is assembled to the opening on the lower end side of the yoke 21 of the assembly 110 (the side opposite to the outer circumference mold 74 side).
  • the central portion of the upper surface of the second mold 72 contacts the lower end surface of the cylindrical portion 13 of the core mold 73 .
  • the outer peripheral edge contacts the lower end surface of the yoke 21 of the connector 6 .
  • the fitting protrusions 79 a of the plurality of connecting portions 79 of the second mold 72 are fitted into the fitting holes 214 a on the lower surface of the plurality of connecting portions 214 of the yoke 21 .
  • the upper ends of the plurality of positioning protrusions 78 of the second mold 72 are in contact with the lower ends of the plurality of molded coils 3 of the connection body 6 .
  • a plurality of forming coils 3 of the connecting body 6 are arranged between a plurality of positioning ribs 77 of the second mold 72 .
  • the fitting hole 214a at the upper end of the yoke 21 and the fitting protrusion 745a of the outer peripheral mold 74 are fitted.
  • the fitting hole 214a at the lower end of the yoke 21 and the fitting protrusion 79a of the second mold 72 are fitted.
  • the relative positions of the outer peripheral die 74 and the second die 72 with respect to the yoke 21 in the circumferential direction are determined.
  • a plurality of positioning ribs 743 of the outer peripheral mold 74 and a plurality of positioning ribs 77 of the second mold 72 position the plurality of forming coils 3 relative to the yoke 21 in the circumferential direction.
  • a plurality of teeth 22 are positioned and fixed to the yoke 21 .
  • the plurality of positioning protrusions 744 of the outer peripheral die 74 and the plurality of positioning protrusions 78 of the second die 72 position the plurality of forming coils 3 relative to the yoke 21 in the central axis L2 direction. From these, the relative arrangement of the plurality of teeth 22 and the plurality of molded coils 3 is positioned, and between each tooth 22 and the molded coil 3 arranged on each tooth 22, the second resin portion of the insulating resin 5 A gap R1 is provided for forming 52 (see FIGS. 19 and 20). By using the molded coil 3, the dimensions of the outer diameter and the inner diameter of the molded coil 3 are formed with high accuracy. Thereby, the gap R1 is ensured with higher accuracy.
  • the bus bar 4 is arranged above (adjacent to) the plurality of molded coils 3 in the central axis L2 direction of the yoke 21 .
  • the molten resin that is poured molds the bus bar 4 to form the first resin portion 51 of the insulating resin 5 .
  • the poured molten resin molds each of the plurality of molded coils 3 to form the third resin portion 53 .
  • the insulating resin 5 is formed on the inner peripheral surface of the yoke 21 by hardening the poured molten resin.
  • the stator 1 is completed by removing the molding die 70 (the first die 71 and the second die 72) from the yoke 21 after the poured molten resin is cured.
  • the stator 1 includes the core 2 , the plurality of molded coils 3 , the busbars 4 , and the insulating resin 5 .
  • the core 2 has a cylindrical yoke 21 and a plurality of teeth 22 projecting inward from the yoke 21 from the inner peripheral surface of the yoke 21 .
  • a plurality of formed coils 3 are arranged on a plurality of teeth 22 .
  • the bus bar 4 is connected to a plurality of molded coils 3 and is connectable to an external circuit.
  • the insulating resin 5 has insulating properties.
  • the insulating resin 5 includes a first resin portion 51 , a second resin portion 52 and a third resin portion 53 .
  • the first resin portion 51 molds the busbar 4 .
  • the second resin portion 52 is arranged between the multiple teeth 22 and the multiple molded coils 3 .
  • the third resin portion 53 molds the plurality of molded coils 3 .
  • the first resin portion 51, the second resin portion 52 and the third resin portion 53 are integrally molded.
  • the first resin portion 51, the second resin portion 52 and the third resin portion 53 are integrally formed. Therefore, the first resin portion 51, the second resin portion 52, and the third resin portion 53 can be formed by forming the resin mold once. Thereby, an increase in cost can be suppressed. Further, since the first resin portion 51 and the third resin portion 53 are integrally formed, the reliability of the connecting portion between the molded coil 3 and the bus bar 4 against external vibration can be improved.
  • the stator manufacturing method includes the teeth/yoke preparation step ST1 (first step), the molded coil/bus bar connection step ST2 (second step), and the stator assembly step ST3 (second step). 3 process), a mold assembly process ST4 (fourth process), and an insulating resin molding process ST5 (fifth process).
  • the teeth and yoke preparation step ST1 a cylindrical yoke 21 and a plurality of teeth 22 to be attached to the inner peripheral surface of the yoke 21 are prepared.
  • a plurality of formed coils 3 and bus bars 4 are prepared, and the plurality of formed coils 3 and bus bars 4 are positioned and interconnected in a predetermined relative arrangement to assemble a connecting body 6.
  • a plurality of teeth 22 are inserted into a plurality of formed coils 3 of the connection body 6, and a jig 10 is used to position the relative arrangement of the connection body 6 and the plurality of teeth 22.
  • the assembly 110 is assembled by attaching the teeth 22 to the inner peripheral surface of the yoke 21 .
  • the molding die 70 is prepared, and in the assembly 110, molding is performed instead of the jig 10 while maintaining the relative arrangement of the plurality of molding coils 3 and the plurality of teeth 22.
  • a mold assembly 130 is assembled by assembling the mold 70 to the yoke 21 .
  • the molten resin is poured into the inner space surrounded by the yoke 21, the plurality of teeth 22, and the molding die 70, and after the molten resin is cured, molding is performed from the yoke 21. Remove the mold 70 .
  • the teeth 22 are attached to the inner peripheral surface of the yoke 21 and protrude from the inner peripheral surface of the yoke 21 .
  • a plurality of formed coils 3 are arranged on a plurality of teeth 22 .
  • the busbar 4 is arranged on one end side of the plurality of molded coils 3 in the central axis L2 direction of the yoke 21 .
  • the first mold 71 and the second mold 72 are attached to the yoke 21 so as to close the openings on both sides of the yoke 21 .
  • the first mold 71 and the second mold 72 position the plurality of molded coils 3 relative to the yoke 21 in the circumferential direction and the relative positions in the direction of the central axis L2, thereby forming the plurality of molded coils 3 and the plurality of teeth. 22, a gap R1 into which the molten resin flows is secured.
  • the first mold 71 and the second mold 72 position the plurality of forming coils 3 relative to the yoke 21 in the circumferential direction and in the direction of the central axis L2. Thereby, gaps R1 into which the molten resin flows are secured between the plurality of molded coils 3 and the plurality of teeth 22 . For this reason, when the molten resin is poured into the internal space surrounded by the yoke 21, the plurality of teeth 22, the first mold 71 and the second mold 72, the molten resin that is poured in forms the plurality of teeth 22 and the plurality of moldings. It also flows into the gap R1 between the coil 3.
  • a resin portion (first resin portion 51) that molds the bus bar 4, a resin portion (third resin portion 53) that molds the plurality of molded coils 3, and a plurality of molded coils 3 are formed by the poured molten resin.
  • a resin portion (second resin portion 52) arranged between the plurality of teeth 22 can be integrally formed. That is, the first resin portion 51, the second resin portion 52, and the third resin portion 53 can be formed by forming the resin mold once. Thereby, an increase in manufacturing cost can be suppressed. Further, since the first resin portion 51 and the third resin portion 53 are integrally formed, the reliability of the connecting portion between the molded coil 3 and the bus bar 4 against external vibration can be improved.
  • a stator (1) of the first aspect comprises a core (2), a plurality of molded coils (3), a busbar (4), and an insulating resin (5).
  • the core (2) has a tubular yoke (21) and a plurality of teeth (22).
  • a plurality of teeth (22) protrude inside the yoke (21) from the inner peripheral surface of the yoke (21).
  • a plurality of forming coils (3) are arranged on a plurality of teeth (22).
  • a bus bar (4) is electrically connected to a plurality of molded coils (3) and is electrically connectable to an external circuit.
  • the insulating resin (5) has insulating properties.
  • the insulating resin (5) includes a first resin portion (51), a second resin portion (52) and a third resin portion (53).
  • the first resin portion (51) molds the bus bar (4).
  • the second resin portion (52) is arranged between the plurality of teeth (22) and the plurality of molded coils (3).
  • a third resin part (53) molds a plurality of molded coils (3).
  • the first resin portion (51), the second resin portion (52) and the third resin portion (53) are integrally molded.
  • the first resin portion (51), the second resin portion (52) and the third resin portion (53) are integrally formed. Therefore, the first resin portion (51), the second resin portion (52) and the third resin portion (53) can be formed by one resin molding. Thereby, an increase in manufacturing cost can be suppressed. In addition, since the first resin portion (51) and the third resin portion (53) are integrally formed, the reliability of the connection between the molded coil (3) and the bus bar (4) against external vibration is improved. can.
  • the first resin portion (51), the second resin portion (52) and the third resin portion (53) are made of the same resin material.
  • the first resin portion (51), the second resin portion (52) and the third resin portion (53) can be formed in one manufacturing process. Thereby, an increase in manufacturing cost can be suppressed.
  • the insulating resin (5) comprises a first resin portion (51), a second resin portion (52) and a third resin portion (53). does not include the boundary surface that separates the
  • the first resin portion (51), the second resin portion (52) and the third resin portion (53) can be integrally formed.
  • a fourth aspect of the stator (1) is, in any one of the first to third aspects, the core (2), the plurality of molded coils (3), the bus bar (4) and the insulating resin (5) are: Integrated by insert molding.
  • the first resin portion (51), the second resin portion (52) and the third resin portion (53) can be integrally formed.
  • the stator manufacturing method of the fifth aspect includes a first step (ST1), a second step (ST2), a third step (ST3), a fourth step (ST4), and a fifth step (ST5).
  • a first step (ST1) a cylindrical yoke (21) and a plurality of teeth (22) to be attached to the inner peripheral surface of the yoke (21) are prepared.
  • a plurality of molded coils (3) and busbars (4) are prepared, and the plurality of molded coils (3) and busbars (4) are positioned and interconnected in a predetermined relative arrangement. to assemble the connector (6).
  • a plurality of teeth (22) are inserted into a plurality of formed coils (3) of the connector (6). Then, using the jig (10), the connecting body (6) and the plurality of teeth (22) are positioned relative to each other, and the plurality of teeth (22) are assembled to the inner peripheral surface of the yoke (21). Assemble the assembly (110).
  • a molding die (70) is prepared, and in the assembled body (110), while maintaining the relative arrangement of the plurality of molding coils (3) and the plurality of teeth (22), A mold assembly (130) is assembled by assembling a molding die (70) to a yoke (21) instead of a jig (10).
  • the molten resin is poured into the internal space surrounded by the yoke (21), the plurality of teeth (22), and the mold (70) to melt. After curing the resin, the mold (70) is removed from the yoke (21).
  • the plurality of teeth (22) are attached to the inner peripheral surface of the yoke (21) and protrude from the inner peripheral surface of the yoke (21).
  • a plurality of forming coils (3) are arranged on a plurality of teeth (22).
  • the busbar (4) is arranged on one end side of the plurality of shaped coils (3) in the central axis (L2) direction of the yoke (21).
  • the first mold (71) and the second mold (72) are attached to the yoke (21) so as to close the openings on both sides of the yoke (21).
  • the first mold (71) and the second mold (72) position the plurality of molded coils (3) relative to the yoke (21) in the circumferential direction and in the direction of the central axis (L2).
  • a gap (K1) into which the molten resin flows is secured between the plurality of molded coils (3) and the plurality of teeth (22).
  • the first die (71) and the second die (72) determine the relative positions of the plurality of forming coils (3) with respect to the yoke (21) in the circumferential direction and relative positions in the central axis (L2) direction. Locate position. This secures a gap (R1) into which the molten resin flows between the plurality of molded coils (3) and the plurality of teeth (22). Therefore, when the molten resin is poured into the internal space surrounded by the yoke (21), the plurality of teeth (22), the first mold (71) and the second mold (72), the poured molten resin It also flows into the gaps (R1) between the plurality of teeth (22) and the plurality of formed coils (3).
  • a resin portion (first resin portion (51)) for molding the bus bar (4) and a resin portion (third resin portion (53)) for molding the plurality of molded coils (3) are formed by the poured molten resin. and a resin portion (second resin portion (52)) arranged between the plurality of molded coils (3) and the plurality of teeth (22) can be integrally formed. That is, the first resin portion (51), the second resin portion (52) and the third resin portion (53) can be formed by forming the resin mold once. Thereby, an increase in manufacturing cost can be suppressed. In addition, since the first resin portion (51) and the third resin portion (53) are integrally formed, the reliability of the connection between the molded coil (3) and the bus bar (4) against external vibration is improved. can.
  • a plurality of blocks (81) corresponding to the plurality of formed coils (3) and holding the corresponding formed coils (3) ) are prepared. At least one (first block 82) of the plurality of blocks (81) further holds a portion of the busbar (4) arranged on the one end side of the corresponding molded coil (3).
  • the relative arrangement of the plurality of molded coils (3) and the bus bar (4) can be accurately positioned to assemble the connector (6). .
  • the jig (10) comprises a core jig (11) and a holding jig (12). have.
  • the core jig (11) is inserted into the central hole of the connector (6) in a state in which a plurality of teeth (22) are inserted into the plurality of formed coils (3). 11) to determine the circumferential position of the plurality of forming coils (3).
  • the holding jig (12) is assembled to one end side of the connection body (6) in a state in which a plurality of teeth (22) are inserted into the plurality of formed coils (3), and a core jig (11 ), the relative arrangement of the plurality of formed coils (3) and the plurality of teeth (22) is positioned.
  • an intermediate assembly (100) By positioning and assembling the connection body (6) and the plurality of teeth (22) in a predetermined relative arrangement using the core jig (11) and the holding jig (12), an intermediate assembly (100) assemble the By inserting the intermediate assembly (100) into the central hole of the yoke (21), the plurality of molded coils (3) of the intermediate assembly (100) are assembled to the inner peripheral surface of the yoke (21). , assemble the assembly (110).
  • the plurality of forming coils (3) and the plurality of teeth (22) are accurately positioned relative to each other. , a plurality of teeth (22) can be assembled to the inner peripheral surface of the yoke (21).
  • the molding die (70) in the seventh aspect, has a first die (71) and a second die (72).
  • the first mold (71) has a core jig (11) and a peripheral mold (74).
  • the second mold (72) is assembled to the opening at one end of the yoke (21), and the outer mold (74) is attached to the yoke (21). It is assembled in the opening on the side opposite to the side of the second mold (72).
  • the second die (72) and the outer die (74) respectively position the circumferential relative positions of the plurality of forming coils (3) with respect to the yoke (21) and the plurality of forming coils with respect to the yoke (21). Position the relative position of (3) in the central axis (L2) direction.
  • the first mold (71) and the second mold (72) can be assembled to the yoke (21) while maintaining assembly accuracy of the intermediate assembly (100).

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)
  • Manufacture Of Motors, Generators (AREA)
PCT/JP2022/018661 2021-05-28 2022-04-25 ステータ及びステータ製造方法 Ceased WO2022249828A1 (ja)

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US18/560,423 US12609575B2 (en) 2021-05-28 2022-04-25 Stator with core having busbars having integrally molded insulating resin
JP2023523367A JPWO2022249828A1 (https=) 2021-05-28 2022-04-25
EP22811102.7A EP4350955A4 (en) 2021-05-28 2022-04-25 Stator and manufacturing method for stator
CN202280036231.0A CN117356018A (zh) 2021-05-28 2022-04-25 定子和定子制造方法

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