WO2023002825A1 - Stator structure, motor, air blower, refrigeration device, method for manufacturing stator structure, and method for manufacturing motor - Google Patents

Abstract

This stator structure (4) comprises a bearing housing (40), a stator (50), and a resin (60). The bearing housing (40) is electrically conductive. The bearing housing (40) also retains ball bearings (21, 22). The stator (50) is disposed on the radial direction outside of the bearing housing (40). The stator (50) includes a stator core (51), and a coil (52) wound around the stator core (51). The resin (60) is disposed between the bearing housing (40) and the stator core (51). The resin (60) is insulating.

Description

Stator structure, motor, blower, refrigerating device, method for manufacturing stator structure, and method for manufacturing motor

It relates to a stator structure, a motor, a blower, a refrigerating device, a method for manufacturing a stator structure, and a method for manufacturing a motor.

Patent Document 1 (Japanese Patent Application Laid-Open No. 2018-148606) discloses a motor including a bearing housing, a stator arranged radially outside the bearing housing, and a rotor arranged radially outside the stator. disclosed.

However, in FIG. 4 of Patent Document 1, the stator core of the stator is in contact with the bearing housing. If the bearing housing is made of electrically conductive material, there is no insulation between the bearing housing and the stator. As a result, the electric potential of the outer rings of the bearings provided on the upper and lower inner peripheral surfaces of the bearing housing increases, so that the electric potential difference between the electric potential of the inner ring and the electric potential of the outer ring of the bearing increases. Therefore, electrolytic corrosion may occur in the bearing.

A stator structure according to the first aspect includes a bearing housing, a stator, and resin. The bearing housing is electrically conductive. The bearing housing also holds the ball bearings. The stator is arranged radially outside the bearing housing. The stator includes a stator core and coils wound around the stator core. A resin is disposed between the bearing housing and the stator core. Resin is insulating.

According to the stator structure of the first aspect, the resin interposed between the bearing housing and the stator core insulates and connects the bearing housing and the stator core. Therefore, even if the bearing housing is made of a conductive material, the resin can ensure insulation between the bearing housing and the stator core. Therefore, it is possible to suppress electrolytic corrosion of the ball bearings held in the bearing housing.

The stator structure according to the second aspect is the stator structure according to the first aspect, in which the outer surface located radially outward of the bearing housing protrudes from the resin on one side in the axial direction.

In the stator structure of the second aspect, the stator structure can be manufactured by fixing the outer surface of the bearing housing to a mold during molding. In this case, the coaxiality between the mold and the bearing housing can be ensured, so the quality of the stator structure can be improved.

A motor according to the third aspect includes the stator structure of the first aspect or the second aspect, a ball bearing, a shaft, and a rotor. A ball bearing is held in a bearing housing. The shaft extends axially and is supported on ball bearings. The rotor is arranged radially outside the stator.

In the motor of the third aspect, by providing the stator structure, it is possible to suppress electrolytic corrosion of the ball bearings held in the bearing housing.

The blower of the fourth aspect includes the motor of the third aspect and a fan. A fan is connected to the shaft.

In the blower of the fourth aspect, by including the motor, electrolytic corrosion of the ball bearings held in the bearing housing can be suppressed.

The refrigeration system of the fifth aspect includes a refrigerant circuit having the fan of the fourth aspect, a condenser, an evaporator, and an expansion mechanism.

In the refrigeration system of the fifth aspect, by providing the blower, it is possible to suppress electrolytic corrosion of the ball bearings held in the bearing housing.

The manufacturing method of the stator structure according to the sixth aspect includes the steps of arranging the stator, arranging the bearing housing, and connecting the stator core. The step of disposing a stator disposes a stator including a stator core and coils wound around the stator core. The step of disposing a bearing housing disposes a conductive bearing housing holding a ball bearing radially inward of the stator. The step of connecting the stator core includes disposing insulating resin between the bearing housing and the stator core and connecting the bearing housing and the stator core with the resin.

According to the manufacturing method of the stator structure of the sixth aspect, the resin is placed between the bearing housing and the stator core, and the bearing housing and the stator core are insulated and connected. Therefore, even if the bearing housing is made of a conductive material, the resin can ensure insulation between the bearing housing and the stator core. Therefore, it is possible to manufacture a stator structure that can suppress electrolytic corrosion of the ball bearings held in the bearing housing.

A method for manufacturing a stator structure according to a seventh aspect is the method for manufacturing a stator structure according to the sixth aspect, wherein the stator structure is formed by placing the stator and the bearing housing in a mold and injecting resin. Manufactured by molding. Molding is performed so that the outer surface of the bearing housing presses against the mold.

In the method of manufacturing the stator structure according to the seventh aspect, the outer surface of the bearing housing can be fixed to the mold during molding. Therefore, coaxiality between the mold and the bearing housing can be ensured.

A stator structure manufacturing method according to an eighth aspect is the stator structure manufacturing method according to the seventh aspect, wherein the thermal expansion coefficient of the material forming the bearing housing is the thermal expansion coefficient of the material forming the mold. bigger than

In the method of manufacturing the stator structure according to the eighth aspect, the bearing housing thermally expands during molding, and the bearing housing spreads outward along the mold, increasing the coaxiality between the bearing housing and the mold. be able to.

A method for manufacturing a stator structure according to a ninth aspect is the method for manufacturing a stator structure according to the seventh aspect or the eighth aspect, in which the mold directs the outer surface of the bearing housing radially inward during molding. It has a pressing surface.

In the method of manufacturing the stator structure according to the ninth aspect, the outer surface of the bearing housing, which has thermally expanded during molding, can be pushed toward the center in the axial direction by the surface of the mold. coaxiality can be increased.

A stator structure manufacturing method according to a tenth aspect is the stator structure manufacturing method according to any one of the seventh to ninth aspects, wherein the step of arranging the bearing housing includes the outer surface of the bearing housing and the mold. and a step of setting the bearing housing in the mold by providing a gap between the

In the method for manufacturing the stator structure according to the tenth aspect, the bearing housing can thermally expand into the gap during molding, so that the degree of coaxiality between the bearing housing and the mold can be increased.

A method of manufacturing a motor according to an eleventh aspect includes steps of manufacturing a stator structure by the method of manufacturing a stator structure according to any one of the sixth to tenth aspects, a holding step, a supporting step, and an arrangement. and a step of: The retaining step retains the ball bearing in the bearing housing. The supporting step supports the axially extending shaft in the ball bearing. The disposing step disposes the rotor radially outside the stator.

With the motor manufacturing method according to the eleventh aspect, it is possible to manufacture a motor that suppresses electrolytic corrosion of the ball bearings held in the bearing housing.

A refrigeration system according to a twelfth aspect includes a refrigerant circuit having a motor manufactured by the method for manufacturing a motor according to the eleventh aspect, a condenser, an evaporator, and an expansion mechanism.

In the refrigerating apparatus of the twelfth aspect, by including the motor manufactured by the motor manufacturing method described above, electrolytic corrosion of the ball bearings held in the bearing housing can be suppressed.

1 is a front view of a fan including a stator structure and a motor according to an embodiment of the present disclosure; FIG. 2 is a cross-sectional view of FIG. 1; FIG. 1 is a front view of a stator structure according to an embodiment of the present disclosure; FIG. FIG. 4 is a cross-sectional view of FIG. 3; 1 is a front view of a bearing housing according to one embodiment of the present disclosure; FIG. FIG. 6 is a cross-sectional view of FIG. 5; FIG. 4A is a cross-sectional view showing a manufacturing process of a stator structure according to an embodiment of the present disclosure; FIG. 4A is a cross-sectional view showing a manufacturing process of a stator structure according to an embodiment of the present disclosure; FIG. 4A is a cross-sectional view showing a manufacturing process of a stator structure according to an embodiment of the present disclosure; FIG. 4A is a cross-sectional view showing a manufacturing process of a stator structure according to an embodiment of the present disclosure; 4 is a flow chart showing manufacturing steps of a stator structure, a motor and a blower according to an embodiment of the present disclosure; 1 is a schematic configuration diagram of a refrigeration system according to an embodiment of the present disclosure; FIG.

A stator structure, a motor, an air blower, a manufacturing method thereof, and a refrigeration system according to an embodiment of the present disclosure will be described below. In the following description, "axial direction" means the central axis A of the motor 3, that is, the direction in which the shaft 5 extends, "radial direction" means the direction orthogonal to the central axis A, and "circumferential direction". is the direction around the central axis A; However, the axial direction, the radial direction, and the circumferential direction in this embodiment are used for specifying the positional relationship, and do not limit the actual directions.

(1) Configuration of Refrigerating Device A refrigerating device 200 shown in Fig. 12 is an air conditioner that air-conditions a room such as a building using a vapor compression refrigerating cycle. The type of refrigeration system 200 is not limited to an air conditioner, and may be a hot water supply system, a floor heating system, a refrigeration system, or the like.

The refrigerating device 200 mainly has an outdoor unit 220 , an indoor unit 230 , and a liquid refrigerant communication pipe 240 and a gas refrigerant communication pipe 250 that connect the outdoor unit 220 and the indoor unit 230 . The vapor compression refrigerant circuit 210 of the refrigeration system 200 is configured by connecting the outdoor unit 220 and the indoor unit 230 via the liquid refrigerant communication pipe 240 and the gas refrigerant communication pipe 250 .

(1-1) Outdoor unit The outdoor unit 220 is installed outdoors (on the roof of the building, near the outer wall surface of the building, etc.). The outdoor unit 220 is connected to the indoor unit 230 via the liquid refrigerant communication pipe 240 and the gas refrigerant communication pipe 250 as described above, and constitutes part of the refrigerant circuit 210 . The outdoor unit 220 mainly has a compressor 221 , a channel switching mechanism 222 , an outdoor heat exchanger 223 and an expansion mechanism 224 .

The compressor 221 is a mechanism that compresses low-pressure refrigerant in the refrigeration cycle to high pressure.

The channel switching mechanism 222 is a mechanism that switches the direction of refrigerant flow when switching between cooling operation and heating operation. During cooling operation, the flow path switching mechanism 222 connects the discharge side of the compressor 221 and the gas side of the outdoor heat exchanger 223, and connects the gas side of the indoor heat exchanger 231 (described later) via the gas refrigerant communication pipe 250. and the suction side of the compressor 221 (see the solid line of the flow path switching mechanism 222 in FIG. 12). Further, during heating operation, the flow path switching mechanism 222 connects the discharge side of the compressor 221 and the gas side of the indoor heat exchanger 231 via the gas refrigerant communication pipe 250, and connects the gas side of the outdoor heat exchanger 223. and the suction side of the compressor 221 (see the dashed line of the flow path switching mechanism 222 in FIG. 12).

The outdoor heat exchanger 223 is a heat exchanger that functions as a refrigerant radiator during cooling operation and functions as a refrigerant evaporator during heating operation. The outdoor heat exchanger 223 has its liquid side connected to the expansion mechanism 224 and its gas side connected to the channel switching mechanism 222 .

The expansion mechanism 224 reduces the pressure of the high-pressure liquid refrigerant that has radiated heat in the outdoor heat exchanger 223 before sending it to the indoor heat exchanger 231 during cooling operation, and transfers the high-pressure liquid refrigerant that has radiated heat in the indoor heat exchanger 231 to the outdoor during heating operation. It is a mechanism for reducing the pressure before sending it to the heat exchanger 223 .

Also, the outdoor unit 220 is provided with the blower 1 . Air blower 1 includes fan 2 and motor 3 . The fan 2 sucks outdoor air into the outdoor unit 220 , supplies the outdoor air to the outdoor heat exchanger 223 , and then discharges the outdoor air to the outside of the outdoor unit 220 . Therefore, the outdoor heat exchanger 223 uses the outdoor air as a cooling source or a heating source to radiate heat or evaporate the refrigerant. Fan 2 is rotationally driven by motor 3 . The details of the blower 1, the fan 2, and the motor 3 will be described later.

(1-2) Refrigerant Connection Pipes Refrigerant connection pipes 240 and 250 are refrigerant pipes that are constructed on-site when the refrigerating apparatus 200 is installed at an installation location such as a building. One end of the liquid refrigerant communication pipe 240 is connected to the expansion mechanism 224 side, and the other end of the liquid refrigerant communication pipe 240 is connected to the liquid side of the indoor heat exchanger 231 . One end of the gas refrigerant communication pipe 250 is connected to the flow path switching mechanism 222 side, and the other end of the gas refrigerant communication pipe 250 is connected to the gas side of the indoor heat exchanger 231 .

(1-3) Indoor Unit The indoor unit 230 is installed indoors (inside the building). The indoor unit 230 is connected to the outdoor unit 220 via the liquid refrigerant communication pipe 240 and the gas refrigerant communication pipe 250 as described above, and constitutes part of the refrigerant circuit 210 . The indoor unit 230 mainly has an indoor heat exchanger 231 and a fan 232 .

The indoor heat exchanger 231 is a heat exchanger that functions as a refrigerant evaporator during cooling operation and as a refrigerant radiator during heating operation. The indoor heat exchanger 231 has a liquid side connected to the liquid refrigerant communication pipe 240 and a gas side connected to the gas refrigerant communication pipe 250 .

The blower 232 includes a fan 233 and a motor 234. The fan 233 draws indoor air into the indoor unit 230 , supplies the indoor air, and then discharges the indoor air to the outside of the indoor unit 230 . Therefore, the indoor heat exchanger 231 uses the indoor air as a cooling source or a heating source to radiate heat or evaporate the refrigerant. Fan 233 is rotationally driven by motor 234 .

(1-4) Operation (1-4-1) Cooling operation When the refrigeration system 200 performs cooling operation, low-pressure refrigerant in the refrigerating cycle is sucked into the compressor 221, compressed to high pressure in the refrigerating cycle, and then discharged. be done. A high-pressure refrigerant discharged from the compressor 221 is sent to the outdoor heat exchanger 223 through the channel switching mechanism 222 . The high-pressure refrigerant sent to the outdoor heat exchanger 223 exchanges heat with the outdoor air supplied by the fan 2 in the outdoor heat exchanger 223 to radiate heat. The high-pressure refrigerant that has released heat in the outdoor heat exchanger 223 is sent to the expansion mechanism 224 and depressurized to a low pressure in the refrigeration cycle. The low-pressure refrigerant decompressed in the expansion mechanism 224 is sent to the indoor heat exchanger 231 through the liquid refrigerant communication pipe 240 . The low-pressure refrigerant sent to the indoor heat exchanger 231 exchanges heat with the indoor air supplied by the fan 233 in the indoor heat exchanger 231 and evaporates. As a result, the indoor air is cooled and blown into the room. The low-pressure refrigerant evaporated in the indoor heat exchanger 231 is sucked into the compressor 221 again through the gas refrigerant communication pipe 250 and the flow path switching mechanism 222 .

(1-4-2) Heating Operation When the refrigerating apparatus 200 performs the heating operation, low-pressure refrigerant in the refrigerating cycle is sucked into the compressor 221, compressed to high pressure in the refrigerating cycle, and then discharged. A high-pressure refrigerant discharged from the compressor 221 is sent to the indoor heat exchanger 231 through the flow path switching mechanism 222 and the gas refrigerant communication pipe 250 . The high-pressure refrigerant sent to the indoor heat exchanger 231 exchanges heat with the indoor air supplied by the fan 233 in the indoor heat exchanger 231 to radiate heat. As a result, the indoor air is heated and blown out into the room. The high-pressure refrigerant that has radiated heat in the indoor heat exchanger 231 is sent to the expansion mechanism 224 through the liquid refrigerant communication pipe 240 and depressurized to the low pressure in the refrigeration cycle. The low-pressure refrigerant decompressed in the expansion mechanism 224 is sent to the outdoor heat exchanger 223 . The low-pressure refrigerant sent to the outdoor heat exchanger 223 exchanges heat with the outdoor air supplied by the fan 2 in the outdoor heat exchanger 223 and evaporates. The low-pressure refrigerant evaporated in the outdoor heat exchanger 223 is sucked into the compressor 221 again through the flow path switching mechanism 222 .

(2) Blower As shown in FIGS. 1 and 2 , the blower 1 includes a fan 2 and a motor 3 . A motor 3 drives the fan 2 to rotate. Fan 2 is, for example, an axial fan.

(3) Motor The motor 3 is an outer rotor type. As shown in FIGS. 2-6, the motor 3 includes a stator structure 4, a shaft 5, a rotor 10, ball bearings 21 and 22, and a cover 30. As shown in FIGS.

(3-1) Shaft Shaft 5 is connected to fan 2 . The shaft 5 is a rod-shaped member extending in the axial direction.

(3-2) Rotor The rotor 10 is connected to the shaft 5 . The rotor 10 rotates around the central axis A. As shown in FIG. As the rotor 10 rotates, the shaft 5 rotates.

The rotor 10 includes a body portion 11, magnets 12, and a yoke 13. The body portion 11 is connected to the shaft 5 . The body portion 11 is made of resin, for example.

The magnet 12 and the yoke 13 are connected to the radial inner end of the main body 11 . The magnet 12 and yoke are axially extending and annular. The magnet 12 is configured such that N poles and S poles are arranged in the circumferential direction. The yoke 13 is arranged radially outside the magnet 12 .

(3-3) Ball Bearings Ball bearings 21 and 22 support the shaft 5 . The ball bearings 21, 22 are made of a conductive material such as metal. Here, the ball bearing 21 is arranged on one side in the axial direction (upper side in FIG. 2). The ball bearing 22 is arranged on the other side in the axial direction (lower side in FIG. 2). Ball bearing 22 is larger than ball bearing 21 .

(3-4) Cover Cover 30 covers rotor 10 . The cover 30 is arranged on one side in the axial direction.

(4) Stator Structure As shown in FIGS. 2 to 4, the stator structure 4 includes a bearing housing 40, a stator 50, and resin 60. As shown in FIG.

(4-1) Bearing Housing As shown in FIG. 2, the bearing housing 40 holds the ball bearings 21 and 22 . The bearing housing 40 is arranged radially outside the ball bearings 21 , 22 .

　As shown in FIGS. 4 to 6, the bearing housing 40 includes a tubular portion 41 and an extension portion 42. As shown in FIGS. The tubular portion 41 and the extension portion 42 are integral. The tubular portion 41 extends in the axial direction. The extending portion 42 extends radially outward from the end portion of the cylindrical portion 41 on the other axial side (lower side in FIGS. 4 to 6).

The bearing housing 40 has an outer surface 43 located radially outward. Here, the outer surface 43 is the radially outer surface of the cylindrical portion 41 .

The outer surface 43 protrudes from the resin 60 on one side in the axial direction. Specifically, one end portion of the outer surface 43 in the axial direction constitutes a protruding portion 44 that protrudes from the resin 60 . The projecting portion 44 does not contact the resin 60 . Here, the projecting portion 44 is exposed.

The edges on one side in the axial direction of the outer surface 43 may be aligned in the circumferential direction, but are separated in the circumferential direction in FIG. In other words, the projections 44 may be continuous in the circumferential direction, but are intermittently positioned in the circumferential direction in FIG.

The bearing housing 40 is made of a conductive material such as metal. Metals are aluminum, SUS, etc., for example.

(4-2) Stator The stator 50 is arranged radially outside the bearing housing 40 . Further, as shown in FIG. 2, the stator 50 is arranged radially inside the magnet 12 and the yoke 13 of the rotor 10 . The stator 50 has an annular shape. The center of the stator 50 coincides with the center axis A of the motor 3 . As shown in FIG. 4 , stator 50 includes a stator core 51 and coils 52 .

The stator core 51 is made of a conductive material. For example, the stator core 51 is formed by laminating magnetic steel plates in the axial direction. Stator core 51 is annular.

The coil 52 is wound around the stator core 51 . Coil 52 excites stator core 51 .

(4-3) Resin As shown in FIGS. 2 and 4, resin 60 is arranged between bearing housing 40 and stator core 51 . Resin 60 connects bearing housing 40 and stator core 51 .

The resin 60 is insulating. The resin 60 of this embodiment is a thermosetting resin. Although the thermosetting resin is not particularly limited, for example, BMC (Bulk Molding Compound) is used.

The resin 60 of this embodiment is arranged entirely between the bearing housing 40 and the stator core 51 . The entire bearing housing 40 is insulated and connected to the stator core 51 by the resin 60 . However, as long as the resin 60 is arranged at least partly between the bearing housing 40 and the stator core 51 , the resin 60 is not limited to this, and the resin 60 is arranged partly between the bearing housing 40 and the stator core 51 . It doesn't have to be. The area where the resin 60 is not arranged is preferably insulating, and is, for example, a space.

In addition, in FIG. 4, the resin 60 covers the entire radial inner surface of the stator core 51 and the entire axial end portions of the coils 52 on one side and the other side. In addition, the resin 60 covers the entire outer surface 43 of the bearing housing 40 excluding the protrusion 44 . Therefore, the resin 60 is arranged between the bearing housing 40 and the stator 50 so as to extend in the axial direction. Furthermore, in FIG. 4 , the resin 60 is arranged to extend radially between the extending portion 42 of the bearing housing 40 and the stator 50 . Furthermore, the resin 60 is arranged so as to extend in the radial direction so as to cover the stator 50 also on one side in the axial direction.

(5) Manufacturing method of stator structure, motor, and blower Next, manufacturing methods of the blower 1 and the motor 3 shown in FIGS. 1 and 2 and the stator structure 4 shown in FIGS. Description will be made with reference to FIG.

In this embodiment, the stator structure 4 is manufactured by molding using the mold 100 . As shown in FIGS. 7 to 10, mold 100 includes fixed mold 101 and movable mold 102 . The fixed mold 101 is a fixed side mold that is fixed during molding. The movable mold 102 is a movable side mold that can be moved.

The coefficient of thermal expansion of the material forming the bearing housing 40 is greater than the coefficient of thermal expansion of the material forming the mold 100 . Here, the material forming the fixed mold 101 and the movable mold 102 is, for example, steel.

As shown in FIGS. 7 and 11, first, a step of arranging the stator 50 including the stator core 51 and the coil 52 wound around the stator core 51 (step S1) is performed. In this step (S1), the stator 50 is set on the stationary mold 101, as shown in FIG. Here, the stator 50 is arranged from above in FIG. 7 toward the cavity of the fixed mold 101 . In addition, when the step (S1) is carried out, the stationary mold 101 is heated to a high temperature (for example, 150° C.).

Next, a conductive bearing housing 40 that holds the ball bearings 21 and 22 is arranged radially inside the stator 50 (step S2). In this step (S2), as shown in FIG. In this state, the bearing housing 40 is radially movable within the cavity of the fixed mold 101 . Also, the bearing housing 40 and the stator 50 can be extracted from the stationary mold 101 .

In this embodiment, the bearing housing 40 is set in the mold 100 with a gap provided between the outer surface 43 of the bearing housing 40 and the mold 100 . Specifically, the bearing housing 40 is set on the fixed mold 101 with a gap provided between the projecting portion 44 of the outer surface 43 and the fixed mold 101 .

Next, as shown in FIG. 8, the fixed mold 101 and the movable mold 102 are clamped (step S3). In this step (S3), the movable mold 102 is moved toward the fixed mold 101, and the fixed mold 101 and the movable mold 102 are brought together.

Next, as shown in FIG. 9, an insulating resin 60 is placed between the bearing housing 40 and the stator core 51, and the bearing housing 40 and the stator core 51 are connected by the resin 60 (step S4). In this step ( S<b>4 ), resin 60 is injected between bearing housing 40 and stator core 51 in the space defined by fixed mold 101 and movable mold 102 . Here, molten resin 60 is poured between bearing housing 40 and stator 50 .

In this embodiment, molding is performed so that the outer surface 43 of the bearing housing 40 presses against the mold 100 . In other words, the bearing housing 40 has an outer surface 43 that bears against the mold 100 during molding. Here, the protruding portion 44 of the outer surface 43 located at the end on one side in the axial direction (lower side in FIG. 9) presses against the stationary die 101 during molding.

The mold 100 has a surface 101a that pushes the outer surface 43 of the bearing housing 40 radially inward during molding. This surface 101a faces radially inward. Here, the projecting portion 44 of the bearing housing 40 and the surface 101a of the stationary mold 101 are in contact with each other during molding.

Here, the mold 100 and the bearing housing 40 in the steps (S2-S4) will be explained. The temperature of the mold 100 is higher than the temperature of the bearing housing 40 before step (S4) is performed. Also, the coefficient of thermal expansion of the material forming the bearing housing 40 is greater than the coefficient of thermal expansion of the material forming the fixed mold 101 . Therefore, the heat of the fixed mold 101 is transferred to the bearing housing 40, and the bearing housing 40 thermally expands. As a result, the bearing housing 40 expands radially outward along the stationary die 101 . At this time, the surface 101a of the fixed die 101 pushes the thermally expanded protrusion 44 of the bearing housing 40 toward the center in the axial direction. Therefore, it can be fixed to the stationary die 101 by the projecting portion 44 of the outer surface 43 of the bearing housing 40 . Further, if a gap is provided between the outer surface 43 of the bearing housing 40 and the fixed die 101 in step (S2), the bearing housing 40 thermally expands so as to fill the gap. In this way, the coaxiality between the bearing housing 40 and the mold 100 can be ensured by making the bearing housing 40 an interference fit along the mold 100 .

Next, as shown in FIG. 10, the mold is opened and the stator structure is taken out (step S5). In this step ( S<b>5 ), the movable mold 102 is moved away from the fixed mold 101 . The bearing housing 40 is cooled by the cooling of the mold 100 or by the air generated by opening the mold. As a result, the bearing housing 40 shrinks, so the stator structure 4 in which the bearing housing 40 and the stator 50 are connected by the resin 60 is removed from the fixed die 101 .

The stator structure 4 including the bearing housing 40, the stator 50 and the resin 60 can be manufactured by performing the above steps (S1 to S5).

Next, prepare the shaft assembly (step S6). In this step (S6), referring to FIG. 2, the rotor 10 and the ball bearings 21 are attached to the shaft 5. Specifically, the ball bearings 21 are arranged so as to support the shaft 5 . Also, the body portion 11 of the rotor 10 is connected to the shaft 5 .

Next, the shaft assembly is attached to the stator structure 4 removed from the mold 100 (step S7). Specifically, the bearing housing 40 holds the ball bearing 21 . Further, the rotor 10 is arranged radially outside the stator 50 .

Next, the ball bearing 22 is fitted into the bearing housing 40 (step S8).

By the above steps (S6 to S8), a step of holding the ball bearings 21 and 22 in the bearing housing 40, a step of supporting the shaft 5 on the ball bearings 21 and 22, and a step of arranging the rotor radially outside the stator. is carried out. Therefore, the motor 3 including the stator structure 4, the ball bearings 21 and 22, the shaft 5, and the rotor 10 can be manufactured by performing the steps (S6 to S8).

Next, the fan 2 is attached to the shaft 5 (step S9). Thereby, the blower 1 including the motor 3 and the fan 2 can be manufactured.

(6) Features (6-1)
The stator structure 4 of this embodiment includes a bearing housing 40 , a stator 50 and resin 60 . Bearing housing 40 is electrically conductive. Also, the bearing housing 40 holds the ball bearings 21 and 22 . The stator 50 is arranged radially outside the bearing housing 40 . Stator 50 includes a stator core 51 and coils 52 wound around stator core 51 . Resin 60 is arranged between bearing housing 40 and stator core 51 . The resin 60 is insulating.

According to the stator structure 4 of this embodiment, the bearing housing 40 and the stator core 51 are insulated and connected by the resin 60 arranged between the bearing housing 40 and the stator core 51 . Therefore, even if the bearing housing 40 is made of a conductive material, the insulation between the bearing housing 40 and the stator core 51 can be ensured by the resin 60 . As a result, it is possible to prevent the high potential of the stator 50 from being transmitted to the bearing housing 40 during the operation of the stator structure 4 , thereby preventing the potential of the outer rings of the ball bearings 21 and 22 from increasing. Therefore, the electric potential of the inner rings of the ball bearings 21 and 22 does not change, and only the electric potential of the outer rings of the ball bearings 21 and 22 can be suppressed from increasing. can. Therefore, electrolytic corrosion of the ball bearings 21 and 22 held in the bearing housing 40 can be suppressed.

As described above, the stator structure 4 of the present embodiment can suppress electrolytic corrosion of the ball bearings 21 and 22, so that the bearing housing 40 made of metal can be used, for example. Since the strength of the bearing housing made of metal is higher than that of the bearing housing made of resin, the strength of the stator structure 4 can also be improved.

(6-2)
Preferably, in the stator structure 4 of the present embodiment, the outer surface 43 positioned radially outwardly of the bearing housing 40 protrudes from the resin 60 on one side in the axial direction.

Thereby, the stator structure 4 can be manufactured by fixing the outer surface 43 of the bearing housing 40 to the mold 100 during molding. In this case, the coaxiality between the mold 100 and the bearing housing 40 can be ensured, so the quality of the stator structure 4 can be improved.

(6-3)
The motor 3 of this embodiment includes a stator structure 4 , ball bearings 21 and 22 , a shaft 5 and a rotor 10 . Ball bearings 21 , 22 are held in bearing housing 40 . Shaft 5 extends axially and is supported by ball bearings 21 , 22 . The rotor 10 is arranged radially outside the stator 50 .

According to the motor 3 of this embodiment, by providing the stator structure 4, electrolytic corrosion of the ball bearings 21 and 22 held in the bearing housing 40 can be suppressed.

(6-4)
A blower 1 of this embodiment includes a motor 3 and a fan 2 . Fan 2 is connected to shaft 5 .

According to the blower 1 of the present embodiment, by providing the motor 3, electrolytic corrosion of the ball bearings 21 and 22 held in the bearing housing 40 can be suppressed.

(6-5)
The refrigeration apparatus 200 of the present embodiment includes the blower 1, the condenser (in FIG. 1, the outdoor heat exchanger 223 or the indoor heat exchanger 231), and the evaporator (in FIG. 1, the indoor heat exchanger 231 or the outdoor heat exchanger 223 ) and an expansion mechanism 224 .

According to the refrigerating apparatus 200 of the present embodiment, by providing the blower 1, electrolytic corrosion of the ball bearings 21 and 22 held in the bearing housing 40 can be suppressed.

(6-6)
The manufacturing method of the stator structure 4 of this embodiment includes the following steps. A stator 50 including a stator core 51 and a coil 52 wound around the stator core 51 is arranged (step S1). Then, the conductive bearing housing 40 that holds the ball bearings 21 and 22 is arranged radially inside the stator 50 (step S2). Then, an insulating resin 60 is placed between the bearing housing 40 and the stator core 51, and the bearing housing 40 and the stator core 51 are connected by the resin 60 (step S4).

According to the method of manufacturing the stator structure 4 of the present embodiment, the resin 60 is arranged between the bearing housing 40 and the stator core 51 so that the bearing housing 40 and the stator core 51 are insulated and connected. Therefore, even if the bearing housing 40 is made of a conductive material, the insulation between the bearing housing 40 and the stator core 51 can be ensured by the resin 60 . Therefore, it is possible to manufacture the stator structure 4 that can suppress electrolytic corrosion of the ball bearings 21 and 22 held in the bearing housing 40 .

(6-7)
Preferably, in the method of manufacturing the stator structure 4 of the present embodiment, the stator structure 4 is manufactured by molding by placing the stator 50 and the bearing housing 40 in a mold 100 and injecting the resin 60 . Molding is performed so that the outer surface 43 of the bearing housing 40 presses against the mold.

Thereby, the outer surface 43 of the bearing housing 40 can be fixed to the mold 100 during molding. Therefore, coaxiality between the mold 100 and the bearing housing 40 can be ensured.

It should be noted that since the inner surface positioned radially inward of the bearing housing 40 does not come into contact with other members, it expands during molding, making it difficult to ensure coaxiality. Therefore, in this embodiment, the mold 100 is fixed on the outer surface 43 of the bearing housing 40 .

(6-8)
Preferably, in the method of manufacturing the stator structure 4 of the present embodiment, the coefficient of thermal expansion of the material forming the bearing housing 40 is larger than the coefficient of thermal expansion of the material forming the mold 100 .

As a result, the bearing housing 40 thermally expands during molding, and the bearing housing 40 expands to the outer peripheral side along the mold 100, so that the degree of coaxiality between the bearing housing 40 and the mold 100 can be increased.

(6-9)
Preferably, in the method of manufacturing the stator structure 4 of the present embodiment, the mold 100 has a surface 101a that presses the outer surface 43 of the bearing housing 40 radially inward during molding.

As a result, the surface 101a of the mold 100 can push the outer surface 43 of the bearing housing 40, which has been thermally expanded during molding, toward the center in the axial direction. can be enhanced.

(6-10)
Preferably, in the method of manufacturing the stator structure 4 of the present embodiment, the step of arranging the bearing housing 40 (Step S2) includes providing a gap between the outer surface 43 of the bearing housing 40 and the mold 100 so that the bearing housing 40 is is set in the mold 100.

As a result, the bearing housing 40 can thermally expand into the gap during molding, so that the degree of coaxiality between the bearing housing 40 and the mold 100 can be increased.

(6-11)
The manufacturing method of the motor 3 of this embodiment includes the following steps. The stator structure 4 is manufactured (steps S1-5). Then, the ball bearings 21 and 22 are held in the bearing housing 40 (steps S6 to S8). Then, the axially extending shaft 5 is supported by the ball bearings 21 and 22 (steps S6 to S8). Then, the rotor 10 is arranged radially outside the stator 50 (steps S6 to S8).

According to the method for manufacturing the motor 3 of this embodiment, the motor 3 that suppresses electrolytic corrosion of the ball bearings 21 and 22 held in the bearing housing 40 can be manufactured.

(6-12)
The manufacturing method of the air blower 1 of this embodiment includes the following steps. The motor 3 is manufactured (steps S1 to S8). Then, the fan 2 is connected to the shaft 5 (step S9).

According to the method for manufacturing the blower 1 of the present embodiment, the blower 1 that suppresses electrolytic corrosion of the ball bearings 21 and 22 held in the bearing housing 40 can be manufactured.

(6-13)
The refrigeration apparatus 200 of the present embodiment includes the blower 1 manufactured by the method for manufacturing the blower 1 (steps S1 to S9), the condenser (in FIG. 1, the outdoor heat exchanger 223 or the indoor heat exchanger 231), A refrigerant circuit 210 having an evaporator (the indoor heat exchanger 231 or the outdoor heat exchanger 223 in FIG. 1) and an expansion mechanism 224 is provided.

In the refrigerating apparatus 200 of the present embodiment, electric corrosion of the ball bearings 21 and 22 held in the bearing housing 40 can be suppressed by including the blower 1 manufactured by the method for manufacturing the blower 1 described above.

(7) Modification (7-1) Modification 1
In the above embodiment, the material forming the mold 100 is different from the material forming the bearing housing 40, but the material is not limited to this. In this modification, the material forming the mold 100 and the material forming the bearing housing 40 are the same. In this case, the bearing housing 40 is locally heated during molding.

(7-2) Modification 2
In the above embodiment, the radially extending resin 60 is arranged between the stator 50 and the extending portion 42 of the bearing housing 40 in the axial direction, but the invention is not limited to this. The resin 60 is arranged between the stator core 51 and the bearing housing 40 according to the structures of the bearing housing 40 and the stator 50 . In this modified example, since the extending portion 42 of the bearing housing 40 is omitted, the radially extending portion of the resin 60 is omitted.

Although embodiments of the present disclosure have been described above, it will be appreciated that various changes in form and detail may be made without departing from the spirit and scope of the present disclosure as set forth in the appended claims. .

Reference Signs List 1: blower 3: motor 4: stator structure 5: shaft 10: rotors 21, 22: ball bearings 40: bearing housing 43: outer surface 50: stator 51: stator core 52: coil 60: resin 100: mold 101a: surface 200 : Refrigeration equipment

JP 2018-148606 A

Claims (11)

1. a conductive bearing housing (40) holding the ball bearings (21, 22);
   a stator (50) disposed radially outside the bearing housing and comprising a stator core (51) and a coil (52) wound around the stator core;
   an insulating resin (60) disposed between the bearing housing and the stator core;
   A stator structure (4) comprising:
2. The stator structure according to claim 1, wherein the outer surface (43) positioned radially outward of the bearing housing protrudes from the resin on one side in the axial direction.
3. A stator structure according to claim 1 or 2;
   a ball bearing retained in the bearing housing;
   a shaft (5) extending axially and supported in said ball bearing;
   a rotor (10) arranged radially outside the stator;
   a motor (3).
4. a motor according to claim 3;
   a fan (2) connected to the shaft;
   A blower (1).
5. A refrigeration system (200) comprising a refrigerant circuit (210) having the blower according to claim 4, a condenser (223, 231), an evaporator (231, 223), and an expansion mechanism (224).
6. disposing a stator (50) comprising a stator core (51) and a coil (52) wound around the stator core;
   placing an electrically conductive bearing housing (40) holding ball bearings (21, 22) inside said stator;
   disposing an insulating resin (60) between the bearing housing and the stator core and connecting the bearing housing and the stator core with the resin;
   A method of manufacturing a stator structure (4), comprising:
7. The stator structure is manufactured by molding by placing the stator and the bearing housing in a mold (100) and injecting the resin,
   7. The method of manufacturing a stator structure according to claim 6, wherein the outer surface (43) of the bearing housing is molded such that it presses against the mold.
8. The method for manufacturing a stator structure according to claim 7, wherein the thermal expansion coefficient of the material forming the bearing housing is larger than the thermal expansion coefficient of the material forming the mold (100).
9. The method of manufacturing a stator structure according to claim 7 or 8, wherein the mold has a surface (101a) that presses the outer surface of the bearing housing radially inward during molding.
10. 10. The step of arranging the bearing housing includes the step of providing a gap between the outer surface of the bearing housing and the mold and setting the bearing housing in the mold. 2. A method for manufacturing the stator structure according to item 1.
11. a step of manufacturing a stator structure by the method for manufacturing a stator structure according to any one of claims 6 to 10;
    holding a ball bearing in the bearing housing;
    supporting an axially extending shaft (5) in said ball bearing;
    placing a rotor (10) radially outward of the stator;
    A method of manufacturing a motor (3), comprising:

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