WO2024034364A1

WO2024034364A1 - Coil, stator and rotating electric machine

Info

Publication number: WO2024034364A1
Application number: PCT/JP2023/026856
Authority: WO
Inventors: 彰彦渡辺; 元輝近藤
Original assignee: パナソニックＩｐマネジメント株式会社
Priority date: 2022-08-12
Filing date: 2023-07-21
Publication date: 2024-02-15

Abstract

A coil (12) used for a rotating electric machine comprises: a wound portion (12a) in which a plurality of turn portions are layered by winding a flat conductive wire by edgewise bending or connecting a plurality of flat conductive wires; and an annular insulative film (12b) inserted into a gap between a first turn portion and a second turn portion which are two adjacent turn portions among the plurality of turn portions.

Description

Coils, stators and rotating electrical machines

The present disclosure relates to a coil, a stator, and a rotating electric machine, and particularly relates to a coil used as a winding coil of a stator in an electric motor.

An electric motor that converts electrical energy into mechanical energy is known as one type of rotating electric machine. Electric motors are used in various products such as household equipment or industrial equipment. For example, electric motors are used in a wide variety of applications, including home appliances such as vacuum cleaners, automobiles, and robots.

In recent years, electric motors are required to have even higher efficiency and lower cost. As a method for improving the efficiency of an electric motor, a technique for increasing the space factor of a winding coil used in a stator of an electric motor is known. By increasing the space factor of the winding coil, it is possible to suppress the loss caused by the current flowing through the winding coil when the motor is driven, thereby improving the efficiency of the motor.

Conventionally, as one technique for increasing the space factor of the winding coil in the stator of an electric motor, it has been proposed to use irregularly shaped coils as the winding coil. As this type of irregularly shaped coil, an edgewise coil produced by edgewise bending a rectangular conductive wire is known. For example, Patent Document 1 discloses a rotating electrical machine that uses edgewise coils as stator winding coils.

Japanese Patent Application Publication No. 2020-178457

Conventionally, rectangular conductive wires constituting coils such as edgewise coils are coated with an insulating film. In particular, for coils used in rotating electric machines, rectangular conductive wires are coated with a highly heat-resistant insulating film.

As a method for coating a rectangular conducting wire with an insulating film, a method of coating or electrodepositing an insulating material on the rectangular conducting wire is known.

However, when a rectangular conducting wire is coated with an insulating film using such a method, there is a problem that the process of coating the rectangular conductive wire with the insulating film becomes complicated and costs increase. Particularly, when coating with a highly heat-resistant insulating film, the cost becomes high.

Furthermore, when the rectangular conducting wire is coated with an insulating film using the above method, the insulating film coated on the edge portion of the rectangular conducting wire becomes thinner than the insulating film coated on the main surface of the rectangular conducting wire. For this reason, when a rectangular conductive wire coated with an insulating film is wound by edgewise bending to produce a wound coil in which a plurality of turn parts are stacked, the insulating film breaks at the bent part where the inner diameter R is small, and the turn part There is a risk that problems such as short circuits may occur. In particular, if a wound coil is manufactured by performing edgewise bending while varying the width of the rectangular conducting wire for each turn, the insulating film is likely to break. In this way, when a rectangular conducting wire coated with an insulating film is wound by edgewise bending, there is a risk that the insulating film will break, making it impossible to obtain a wound coil having desired electrical performance. In other words, the quality of the wound coil deteriorates.

The present disclosure has been made to solve such problems, and provides a coil, a stator, and a coil that can be produced at low cost and with high quality by winding a rectangular conducting wire by edgewise bending. The purpose is to provide rotating electrical machines, etc.

In order to achieve the above object, one aspect of the coil according to the present disclosure is a coil used in a rotating electric machine, which is formed by winding a rectangular conducting wire by edgewise bending or by connecting a plurality of rectangular conducting wires. a winding part in which turn parts are laminated, and an annular insulating film inserted between a first turn part and a second turn part, which are two adjacent turn parts in the plurality of turn parts. .

Further, one aspect of the stator according to the present disclosure includes a stator core having a plurality of teeth, and a winding coil wound around each of the plurality of teeth, and the winding coil is the above-mentioned coil. .

Further, one aspect of the rotating electric machine according to the present disclosure includes the stator described above and a rotor that rotates due to the magnetic force of the stator.

According to the present disclosure, a coil formed by winding a rectangular conducting wire by edgewise bending can be manufactured at low cost and with high quality.

FIG. 1 is a sectional view of an electric motor according to an embodiment. FIG. 2 is a perspective view of the coil block according to the embodiment. FIG. 3 is an exploded view of the coil block according to the embodiment. FIG. 4 is a cross-sectional view of the coil block taken along line IV-IV in FIG. 2. FIG. 5 is a cross-sectional view of the coil block taken along line VV in FIG. 2. FIG. 6 is a diagram showing an insulating film in a coil according to an embodiment. FIG. 7 is a front view of the coil according to the embodiment. FIG. 8 is a diagram illustrating an example of a method for manufacturing a coil according to an embodiment. FIG. 9 is a diagram showing another example of the method for manufacturing the coil according to the embodiment. FIG. 10 is a diagram showing an insulating film in a coil according to Modification Example 1. FIG. 11 is a front view of a coil according to modification example 1. FIG. 12 is a cross-sectional view of a coil block according to modification 2. FIG. 13 is a front view of a coil according to modification 3. FIG. 14 is a perspective view of an insulating film in a coil according to modification example 4.

Hereinafter, embodiments of the present disclosure will be described. Note that the embodiments described below each represent a specific example of the present disclosure. Therefore, the numerical values, components, arrangement positions and connection forms of the components, steps and order of steps, etc. shown in the following embodiments are merely examples and do not limit the present disclosure. Therefore, among the constituent elements in the following embodiments, constituent elements that are not described in the independent claims representing the most important concept of the present disclosure will be described as arbitrary constituent elements.

Furthermore, each figure is a schematic diagram and is not necessarily strictly illustrated. In addition, in each figure, the same code|symbol is attached to the substantially the same structure, and the overlapping description is omitted or simplified.

Furthermore, in this embodiment, the radial direction of the stator 10 and rotor 20 is referred to as a "radial direction", and the rotational direction of the rotor 20 is referred to as a "circumferential direction". In other words, the direction in which the rotating shaft 23 is centered around the axial center C and extends from the axial center C is the "radial direction", and the direction in which the rotating shaft 23 is centered around the axial center C and goes around the axial center C is the "circumferential direction". . Therefore, the "radial direction" is a direction perpendicular to the direction of the axis C of the rotating shaft 23. Note that in this specification, the terms "upper" and "lower" do not necessarily refer to the upper direction (vertically upward) and the downward direction (vertically downward) in absolute spatial recognition.

(Embodiment)
In the following embodiments, an electric motor will be described as an example of a rotating electric machine.

First, the overall configuration of the electric motor 1 according to the embodiment will be described using FIG. 1. FIG. 1 is a sectional view of an electric motor 1 according to an embodiment. FIG. 1 shows a cross section taken along a plane perpendicular to the direction of the axis C of the rotating shaft 23 of the rotor 20.

As shown in FIG. 1, the electric motor 1 includes a stator 10 and a rotor 20. Stator 10 and rotor 20 are arranged facing each other. The electric motor 1 in this embodiment is an inner rotor type motor in which the rotor 20 is arranged inside the stator 10. In addition to the stator 10 and the rotor 20, the electric motor 1 also includes parts such as a motor case and a bearing that pivotally supports the rotating shaft 23, but for the sake of convenience, illustration and description of these parts will be omitted.

The stator 10 (stator) is arranged to face the rotor 20 with an air gap between the stator 10 and the rotor 20. A minute air gap exists between the surface of the rotor 20 and the surface of the stator 10. In this embodiment, stator 10 is arranged to surround rotor core 21 of rotor 20 .

The stator 10 generates magnetic force that acts on the rotor 20. Specifically, the stator 10 is configured to generate magnetic flux in the air gap surface between the stator 10 and the rotor core 21 of the rotor 20 . For example, the stator 10 is configured such that north poles and south poles are alternately generated in the air gap surface with the rotor core 21 in the circumferential direction.

As shown in FIG. 1, in this embodiment, the stator 10 includes a coil 12 and a stator core 11.

The coil 12 is a stator coil provided in the stator 10 as a winding coil. The coil 12 is an armature winding of the stator 10 and is wound around the stator core 11. Specifically, the coil 12 is wound around each of the plurality of teeth 11a of the stator 10. Therefore, a plurality of coils 12 are used in the stator 10. Each of the plurality of coils 12 is wound around each of the plurality of teeth 11a.

The plurality of coils 12 are arranged at equal intervals along the circumferential direction so as to surround the rotor 20. Each coil 12 is housed in each slot 11c of the stator 10. The coil 12 is attached to the teeth 11a via an insulator (not shown in FIG. 1).

In this embodiment, one coil block 100 is composed of one coil 12, one insulator 13, and one tooth 11a. The electric motor 1 has a plurality of coil blocks 100. Specifically, in the electric motor 1 shown in FIG. 1, 18 coil blocks 100 are used. Each of the plurality of coil blocks 100 is fixed to the stator core 11 by fitting the teeth 11a of each coil block 100 into the yoke 11b. Note that detailed configurations of the coil block 100 and the coil 12 will be described later.

The stator core 11 is an iron core that becomes the core of the stator 10. In this embodiment, the stator core 11 includes a plurality of teeth 11a and an annular yoke 11b.

Each of the plurality of teeth 11a protrudes toward the axis C of the rotating shaft 23 of the rotor 20. Specifically, the plurality of teeth 11a are provided radially in a direction (radial direction) orthogonal to the axis C of the rotating shaft 23.

A slot 11c for arranging the coil 12 is formed between two adjacent teeth 11a. That is, the slot 11c of the stator 10 is an area between two adjacent teeth 11a. The plurality of teeth 11a are arranged at equal intervals along the circumferential direction while forming slots 11c between two adjacent teeth 11a. In this embodiment, the stator 10 has 18 teeth 11a, so the number of slots in the stator 10 is 18.

Each tooth 11a extends radially inward from the annular yoke 11b. That is, the yoke 11b is a back yoke formed on the outside of each tooth 11a. Each tooth 11a is fitted and fixed to a yoke 11b.

The yoke 11b may be divided into a plurality of parts, or may be configured as one piece. When the yoke 11b is divided into a plurality of parts, the yoke 11b is configured by connecting the plurality of divided circular arc yokes in an annular shape. For example, the yoke 11b can be configured by six equally divided circular arc yokes. In this case, three teeth 11a are fixed to one arcuate yoke at equal intervals.

The teeth 11a and the yoke 11b are each a laminate formed by laminating a plurality of electromagnetic steel sheets. Each of the plurality of electromagnetic steel plates is, for example, a punched steel plate formed into a predetermined shape. Note that the teeth 11a and the yoke 11b may be bulk bodies made of a magnetic material.

Each of the plurality of teeth 11a is a magnetic pole tooth, and generates magnetic force when the coil 12 is energized. In this embodiment, the plurality of coils 12 in the stator 10 are electrically connected as three-phase windings so that the rotor 20 rotates as a three-phase synchronous motor. Specifically, the plurality of coils 12 are configured by unit coils for each of three phases, U-phase, V-phase, and W-phase, which are electrically different in phase by 120 degrees from each other. That is, the coil 12 attached to each tooth 11a is energized and driven by three-phase alternating current that is energized in units of U phase, V phase, and W phase. Thereby, main magnetic flux for rotating the rotor 20 is generated in each tooth 11a.

The rotor 20 (rotor) is rotated by the magnetic force of the stator 10. The rotor 20 also generates magnetic force. Specifically, the rotor 20 has a configuration in which a plurality of N poles and S poles that generate magnetic flux are alternately and repeatedly present in the circumferential direction. Thereby, the rotor 20 generates a magnetic force that acts on the stator 10. In this embodiment, the direction of the magnetic flux generated from the rotor 20 is a direction perpendicular to the direction of the axis C of the rotating shaft 23 (axial center direction). That is, the direction of the magnetic flux generated by the rotor 20 is the radial direction.

The rotor 20 has a rotor core 21, a plurality of permanent magnets 22, and a rotating shaft 23. The rotor 20 rotates about the axis C of the rotating shaft 23 as a rotation center. That is, the rotating shaft 23 becomes the center of rotation of the rotor 20.

In this embodiment, the rotor 20 is an embedded permanent magnet rotor (IPM rotor) in which a permanent magnet 22 is embedded in a rotor core 21. Therefore, electric motor 1 in this embodiment is an IPM motor.

The rotor core 21 is an iron core that becomes the core of the rotor 20. In this embodiment, the rotor core 21 is a laminate in which a plurality of electromagnetic steel sheets are laminated in the direction of the axis C of the rotating shaft 23 (axial direction). Each of the plurality of electromagnetic steel plates is, for example, a punched steel plate formed into a predetermined shape. The plurality of electromagnetic steel plates are fixed to each other by caulking, for example. Note that the rotor core 21 is not limited to a laminate of a plurality of electromagnetic steel plates, but may be a bulk body made of a magnetic material.

The permanent magnet 22 is arranged in a magnet insertion hole provided in the rotor core 21. In this embodiment, ten magnet insertion holes are provided in the rotor core 21, and a plate-shaped permanent magnet 22 is inserted into each magnet insertion hole. As an example, permanent magnet 22 is a sintered magnet. Note that the permanent magnet 22 may be a bonded magnet.

The rotating shaft 23 is an elongated shaft, for example, a metal rod. The rotating shaft 23 is fixed to the rotor core 21. Specifically, the rotating shaft 23 is inserted into a through hole provided at the center of the rotor core 21 and fixed to the rotor core 21 so as to extend on both sides of the rotor core 21 in the direction of the axis C. The rotating shaft 23 is fixed to the rotor core 21 by, for example, press-fitting or shrink-fitting into a through hole of the rotor core 21. In the electric motor 1, one of the parts of the rotating shaft 23 that protrudes from the rotor core 21 functions as an output shaft. For example, a load such as a rotating fan is attached to the rotating shaft 23. Although not shown, the rotating shaft 23 is rotatably supported by a bearing such as a bearing.

In the electric motor 1 configured as described above, when the coil 12 of the stator 10 is energized, a field current flows through the coil 12 and a magnetic field is generated in the stator 10. As a result, magnetic flux directed from the stator 10 toward the rotor 20 is generated. Specifically, magnetic flux directed toward the rotor 20 is generated from each of the teeth 11a of the stator core 11 of the stator 10. On the other hand, in the rotor 20, a magnetic flux passing through the stator 10 is generated by the permanent magnet 22 arranged in the rotor core 21. The magnetic force generated by the interaction between the magnetic flux generated by the stator 10 and the magnetic flux generated from the permanent magnets 22 of the rotor 20 becomes a torque that rotates the rotor 20, and the rotor 20 rotates.

Next, detailed configurations of the coil block 100 and coil 12 used in the electric motor 1 according to the present embodiment will be explained using FIGS. 2 to 7 while referring to FIG. 1.

FIG. 2 is a perspective view of the coil block 100 according to the embodiment, and FIG. 3 is an exploded view of the coil block 100. 4 is a cross-sectional view of the coil block 100 taken along the line IV--IV in FIG. 2, FIG. 5 is a cross-sectional view of the coil block 100 taken along the line V-V in FIG. 2, and FIG. It is a figure which shows the insulating film 12b in the coil 12 which concerns, and FIG. 7 is a front view of the coil 12 which concerns on embodiment.

As shown in FIGS. 2 and 3, the coil block 100 includes a coil 12, an insulator 13, and teeth 11a. In the coil block 100, the coil 12 is attached to the teeth 11a via an insulator 13.

The insulator 13 is interposed between the coil 12 and the teeth 11a, as shown in FIGS. 2 to 5. The insulator 13 is a cylindrical insulating frame that covers the teeth 11a. The insulator 13 is made of an insulating resin material such as polybutylene terephthalate (PBT). In this embodiment, the insulator 13 is separated into a first frame 13a and a second frame 13b, and after the coil 12 is attached to the cylindrical portion of the first frame 13a, the second frame 13b is attached to the second frame 13b. The coil 12 can be attached to the insulator 13 by fitting it into the cylindrical portion of the frame 13a. Further, the coil block 100 can be manufactured by inserting the teeth 11a into the cylindrical portion of the insulator 13 to which the coil 12 is attached.

As shown in FIGS. 4 and 5, the coil 12 includes a winding portion 12a formed by winding a plate-shaped conductor, and an insulating film 12b inserted into the winding portion 12a.

The coil 12 is an irregularly shaped coil, and a flat rectangular conducting wire is used as the plate-shaped conductor that constitutes the winding portion 12a. The winding portion 12a in this embodiment is a winding portion having a structure in which a plurality of turn portions are stacked by winding a rectangular conducting wire by edgewise bending. In other words, the coil 12 is an edgewise coil. The coil 12 in this embodiment is a high-density molded coil. By using the coil 12 configured in this way, a higher space factor can be obtained compared to a round wire coil configured with a round wire. For example, the space factor of the coil 12 in this embodiment is 90% or more.

The winding part 12a has a rectangular flat conductor wire that constitutes the first turn at the beginning of winding as a winding start turn part, and a rectangular flat conductor wire that constitutes the n-th turn (n is an integer of 2 or more) at the end of winding. Assuming that this is the winding end turn part, the structure is such that n turn parts from the first turn to the nth turn are stacked.

Specifically, the winding portion 12a is formed by winding a rectangular conductive wire having a constant thickness so that each turn has a substantially rectangular shape. is formed into a substantially rectangular frame shape. Therefore, when the winding part 12a is viewed from the stacking direction of the plurality of turn parts, the shape of the winding part 12a is a substantially rectangular frame shape. In other words, the winding portion 12a made of n turns of rectangular conducting wire from the first turn to the nth turn is formed into a substantially rectangular frame shape having four sides when viewed from the radial direction of the stator 10.

In the winding portion 12a, the width of the rectangular conducting wire differs depending on the turn portion. For example, the winding portion 12a is formed such that the width of the rectangular conducting wire gradually increases or decreases from the first turn to the nth turn. In this embodiment, the rectangular conductive wire is spirally wound so that the plurality of turn parts in the winding part 12a have the same inner diameter and gradually increase the outer diameter. In this case, as shown in FIG. 1, in the coil 12, the turn portion with the smallest external dimension is located on the tip side of the teeth 11a, and the turn portion with the largest external dimension is located on the root side of the teeth 11a (on the yoke 11b side). It is arranged like this. In addition, the turn part with the smallest external dimension may be the start turn part, and the turn part with the largest external dimension may be the end turn part, or the turn part with the smallest external dimension may be the end turn part, and the turn part with the smallest external dimension may be the end turn part. The largest turn portion may be used as the starting turn portion. Furthermore, the widths of the rectangular conducting wires in all the turn parts in the winding part 12a may be made the same.

As the rectangular conducting wire constituting the winding portion 12a, a metal plate whose main component is a low-resistance metal material such as copper or aluminum can be used. In this embodiment, a metal plate made of a copper alloy is used as the rectangular conductive wire constituting the winding portion 12a.

The surface of the rectangular conducting wire constituting the winding portion 12a is not coated with an insulating film. In other words, the surface of the rectangular conducting wire constituting the winding portion 12a is an exposed surface. In this embodiment, the surface of the metal plate constituting the winding portion 12a is exposed.

Therefore, an insulating film 12b is inserted into the winding part 12a in order to insulate the rectangular conductive wires of two adjacent turn parts in the winding part 12a. Specifically, if two adjacent turns in the plurality of turns in the winding portion 12a are defined as a first turn (k turn) and a second turn (k+1 turn), the results are shown in FIGS. 4 and 5. As shown, the insulating film 12b is inserted between the first turn section and the second turn section. The insulating film 12b may be in contact with either one of the main surfaces of the mutually opposing flat conductive wire of the first turn portion and the second turn portion, which are two adjacent turn portions. In this embodiment, the insulating film 12b is in contact with each of the main surfaces of the flat conductive wire facing each other in the first turn part and the second turn part. In other words, the insulating film 12b is in contact with the main surface of the rectangular conducting wire constituting the first turn, which is one of the two adjacent turns, and also contacts the second turn, which is the other of the two adjacent turns. It is in contact with the main surface of the constituent rectangular conducting wire. Note that the width of the rectangular conducting wire constituting the first turn portion is different from the width of the rectangular conducting wire constituting the second turn portion.

On the other hand, the outer end surface (outer side surface) of the rectangular conducting wire constituting the winding portion 12a is not covered with the insulating film 12b and is exposed. That is, in each turn portion of the winding portion 12a, the outer end surface of the rectangular conducting wire is exposed to the outside air.

Furthermore, the inner end surface (inner side surface) of the rectangular conducting wire constituting the winding portion 12a is not covered with the insulating film 12b, similarly to the outer end surface of the rectangular conducting wire. Therefore, in this embodiment, the insulating film 12b is in contact with only the main surface of the main surface and end surface of the rectangular conducting wire that constitutes the winding portion 12a. In this embodiment, the insulating film 12b is in contact with the entire main surface of the rectangular conducting wire that constitutes the winding portion 12a. In this way, since the inner end surface of the rectangular conducting wire constituting the winding portion 12a is not covered with the insulating film 12b, the insulating film 12b is not present in the portion of the coil 12 that contacts the insulator 13. Specifically, the insulating film 12b is not in contact with the entire surface of the insulator 13. Therefore, the inner end surface of the rectangular conducting wire constituting the winding portion 12 a is in contact with the insulator 13 .

In this embodiment, the insulating film 12b is provided for each turn of the winding portion 12a. In other words, the coil 12 includes a plurality of insulating films 12b separated from each other. Specifically, the coil 12 has a structure in which one turn part made of a rectangular conductive wire and one insulating film 12b are laminated alternately.

As shown in FIG. 6, each insulating film 12b is annular. Specifically, each insulating film 12b has a substantially rectangular ring shape. In this case, each of the plurality of insulating films 12b has the same inner diameter, similar to the plurality of turn parts of the winding part 12a. On the other hand, the outer diameter of the plurality of insulating films 12b gradually increases, similar to the plurality of turn parts of the winding part 12a. Therefore, the plurality of insulating films 12b have different widths depending on the turn portions of the winding portion 12a.

The insulating film 12b is a thin insulating member in the form of a film or sheet. The thickness of the insulating film 12b is constant, for example, 20 μm to 50 μm. Further, as the insulating material constituting the insulating film 12b, a resin material such as polyphenylene sulfide (PPS), polyethylene naphthalate (PEN), or polyethylene terephthalate (PET) can be used.

As shown in FIG. 6, each insulating film 12b has a cutout portion 12b1. Specifically, the notch portion 12b1 is a cut portion where the annular insulating film 12b is cut at one location. In this way, each insulating film 12b does not have a continuous closed annular shape. As shown in FIG. 7, the cutout portion 12b1 of the insulating film 12b is a portion through which a rectangular conducting wire forming each of the plurality of turn portions of the winding portion 12a passes.

It is preferable that the insulating films 12b overlap at the cutout portion 12b1. That is, one end of the insulating film 12b at the notch 12b1 and the other end of the insulating film 12b at the notch 12b1 preferably overlap when viewed from the radial direction of the stator 10.

In addition, in the plurality of turns of the winding part 12a, the notches 12b1 of the plurality of insulating films 12b are formed when viewed from the lamination method of the plurality of turns (that is, when viewed from the radial direction of the stator 10). ), preferably present at different positions in two adjacent turn parts.

As shown in FIG. 8, the winding portion 12a can be produced by spirally winding a rectangular conducting wire 12M having a constant thickness so that each turn portion is rectangular. In this case, a rectangular conductive wire having a constant thickness and width is rolled at a predetermined portion and wound into a rectangular spiral while changing the width for each turn, and an insulating film 12b having a different width for each turn. The coil 12 can be manufactured by sequentially sandwiching the two. Alternatively, a rectangular conducting wire that has been preformed with different widths along the way is bent at a predetermined position and wound into a rectangular spiral to form multiple turns, and each turn is covered with an insulating film. The coil 12 may be manufactured by sandwiching the coil 12b.

At this time, the rectangular conducting wire 12M and the insulating film 12b of each turn part of the winding part 12a can be joined by thermocompression bonding or ultrasonic waves for each turn part after edgewise bending. In this case, the rectangular conducting wire 12M and the insulating film 12b may be joined intermittently in a pot shape, or may be joined continuously. In this way, by joining the rectangular conducting wire 12M and the insulating film 12b after edgewise bending, it is possible to suppress wrinkles or misalignment of the insulating film 12b. Alternatively, a part of the insulating film 12b (for example, a part that does not come in contact with a bending jig for bending the flat conductor 12M) is joined to the flat conductor 12M before edgewise bending, and another part (a part that the bending jig contacts) After edgewise bending the part), it may be joined to the rectangular conducting wire 12M. Thereby, it is possible to further suppress wrinkles and positional deviations in the insulating film 12b.

Note that the rectangular conducting wire 12M and the insulating film 12b are not joined for each turn, but after forming all the turns, the edgewise bent coil-shaped winding portion 12a is stretched, as shown in FIG. In this state, the insulating film 12b may be inserted between the turn parts, the winding part 12a may be contracted, and the insulating film 12b may be fixed to the rectangular conducting wire 12M. FIG. 9 shows a state in which the winding portion 12a is stretched and the insulating film 12b is inserted only at three locations between the turn portions. When inserting the insulating film 12b after forming all the turn parts in this way, an insulating tape having an adhesive layer is used as the insulating film 12b, and the insulating tape is bonded to the rectangular conductor 12M, so that the insulating film 12b is bonded by the adhesive layer. It may be fixed to the rectangular conducting wire 12M. Alternatively, the insulating film 12b may be fixed to the rectangular conducting wire 12M with varnish. Note that the method of fixing the insulating film 12b using an insulating tape or varnish may be used when joining the rectangular conducting wire 12M and the insulating film 12b at each turn portion.

As described above, in the coil 12 according to the present embodiment, the rectangular conducting wire between each turn in the winding part 12a is insulated and separated by inserting the insulating film 12b into each turn of the winding part 12a. . Therefore, the current supplied to the coil 12 is applied to the rectangular conductive wire formed in a spiral shape from the first turn of the first turn to the end of the nth turn, or from the last turn to the first turn of the winding. It will flow along.

As described above, the coil 12 according to the present embodiment has a winding part 12a in which a plurality of turn parts are stacked by winding a rectangular conducting wire by edgewise bending, and two adjacent turn parts in the plurality of turn parts. It includes an annular insulating film 12b inserted between a first turn part (kth turn part) and a second turn part ((k+1)th turn part).

With this configuration, it is possible to insulate and separate the flat conductive wires in two adjacent turn portions in the winding portion 12a without coating the flat conductive wires with an insulating film. Specifically, an inexpensive insulating film 12b made of resin is used to insulate and separate the rectangular conductive wires of two adjacent turn portions. This eliminates the need for the step of coating the rectangular conductive wire with an insulating film, so the coil 12 can be manufactured at a lower cost than when a coil is manufactured using a rectangular conductive wire coated with an insulating film. Furthermore, when a rectangular conducting wire coated with an insulating film is bent edgewise as in the conventional method, the insulating film may break at the bending part, resulting in a short circuit between the turn parts, but in this embodiment, the insulating film is Since the film is not coated, the insulating film will not break and short circuit between the turn parts will not occur. Thereby, the coil 12 having desired electrical performance can be manufactured, and thus the coil 12 of high quality can be obtained. As described above, according to the present embodiment, the coil 12 formed by winding the rectangular conducting wire by edgewise bending can be manufactured at low cost and with high quality.

Further, in the coil 12 according to the present embodiment, the insulating film 12b is formed on the main surface of the rectangular conducting wire constituting the first turn portion, which is one of the two adjacent turn portions, and on the other of the two adjacent turn portions. It is in contact with each of the main surfaces of the rectangular conducting wire constituting a certain second turn portion. That is, one insulating film 12b is inserted between the first turn part and the second turn part.

With this configuration, the coil 12 can be manufactured at low cost.

Further, in the coil 12 according to the present embodiment, the width of the rectangular conducting wire constituting the first turn portion, which is one of the two adjacent turn portions, and the second turn portion, which is the other of the two adjacent turn portions. The widths of the rectangular conducting wires that constitute the wires are different.

When edgewise bending a rectangular conducting wire coated with an insulating film, if the width is made different for each turn, the insulating film will be more likely to break, and a short circuit between the turns will be more likely to occur. On the other hand, in this embodiment, even if the winding portion 12a is formed with a different width for each turn portion, since the rectangular conductive wire is not coated with an insulating film, the insulating film may be broken and the turn portions may be broken. There will be no short circuit between the two.

Furthermore, in the coil 12 according to the present embodiment, the insulating film 12b is provided for each turn of the winding portion 12a.

With this configuration, the insulating film 12b can be easily inserted between the rectangular conductive wires of two adjacent turn parts in the winding part 12a.

Furthermore, in the coil 12 according to the present embodiment, the insulating film 12b has a cutout portion 12b1 through which a rectangular conducting wire forming each of the plurality of turn portions in the winding portion 12a passes.

With this configuration, even if the rectangular conducting wire constituting the winding portion 12a is wound in a spiral shape, the insulating film 12b can be easily inserted between two adjacent turn portions.

Furthermore, in the coil 12 according to the present embodiment, the insulating films 12b preferably overlap at the cutout portions 12b1.

With this configuration, it is possible to reduce the gap created by providing the cutout portion 12b1 in the insulating film 12b.

Furthermore, in the coil 12 according to the present embodiment, the cutout portions 12b1 of the plurality of insulating films 12 are located at different positions in two adjacent turn portions when viewed from the lamination method of the plurality of turn portions. Good to have.

With this configuration, the insulation of the coil 12 can be improved. Further, as described above, when the insulating films 12b are configured to overlap at the cutout portions 12b1, the presence of the cutout portions 12b1 at different positions in two adjacent turn portions improves the insulation. The presence of the overlapping portion of the film 12b can effectively prevent the entire coil 12 from increasing in size.

Furthermore, in the coil 12 according to the present embodiment, the inner diameter dimensions of each of the plurality of insulating films 12b are the same.

With this configuration, the coil 12 having an inner shape that follows the outer shape of the teeth 11a can be easily manufactured.

Furthermore, in the coil 12 according to the present embodiment, the outer diameter of the plurality of insulating films 12b gradually increases.

With this configuration, it is possible to easily manufacture the coil 12 having the winding portion 12a in which the width of the rectangular conducting wire becomes thicker for each turn portion.

Further, the coil 12 according to this embodiment is used as a winding coil of the stator 10. Specifically, the stator 10 includes a stator core 11 having a plurality of teeth 11a, and a coil 12 each wound around each of the plurality of teeth 11a.

By using the coil 12 in this embodiment, a winding process is not necessary when placing the coil 12 on the teeth 11a. Specifically, the stator 10 including the coil 12 can be manufactured by attaching the coil block 100, in which the coil 12 is attached to the teeth 11a via the insulator 13, to the yoke 11b. In this way, since the winding step is not necessary, it is possible to suppress the positional shift of the coil 12.

(Modified example)
Although the coil 12 and the like according to the present disclosure have been described above based on the embodiments, the present disclosure is not limited to the above embodiments.

For example, in the above embodiment, only one notch 12b1 is formed in one insulating film 12b, but the present invention is not limited to this. Specifically, as shown in FIG. 10, two notches 12b1 may be formed in the insulating film 12bA, and the insulating film 12bA may be divided into two film pieces each having a substantially L-shape. In this case, the coil 12A shown in FIG. 11 can be manufactured by inserting the insulating film 12bA shown in FIG. 10 between two adjacent turn parts in the winding part 12a. In this way, by using the insulating film 12bA divided into two parts, even if the rectangular conductive wire constituting the winding part 12a is spirally wound, the insulating film 12bA can be separated between two adjacent turn parts. can be easily inserted.

Furthermore, in the above embodiment, the plurality of insulating films 12b in the coil 12 have different widths for each turn, but the width is not limited to this. For example, like the coil block 100B shown in FIG. 12, the plurality of insulating films 12bB in the coil 12B may have the same width. In this case, the insulating film 12bB covers the main surface of the rectangular conducting wire constituting the first turn portion, which is one of the two adjacent turn portions, and the second turn portion, which is the other of the two adjacent turn portions. It is in contact with a portion of each of the main surfaces of the rectangular conducting wires. There is a portion where the insulating film 12bB is not present in the gap between the main surface of the rectangular conducting wire constituting the first turn portion and the main surface of the rectangular conducting wire constituting the second turn portion, and in this portion, There is an intervening air layer. In other words, in locations where the insulating film 12bB is not present, the rectangular conductive wires of two adjacent turn portions are air-insulated from each other. In this way, by making the widths of the plurality of insulating films 12bB the same, the coil 12B can be manufactured at even lower cost.

Furthermore, in the above embodiment, the insulating film 12b does not protrude from the corner of the rectangular conducting wire that constitutes the turn portion of the winding portion 12a, but the present invention is not limited to this. Specifically, as in the coil 12C shown in FIG. 13, the insulating film 12bC protrudes from each corner of at least the rectangular conducting wire constituting the first turn portion and the rectangular conducting wire constituting the second turn portion. may be formed. Since the corners of the winding part 12a are prone to electric current concentration and dielectric breakdown, as shown in FIG. Even if the outer end face of the rectangular conducting wire at the corner of 12a is exposed, it is possible to effectively prevent dielectric breakdown from occurring. In other words, it is possible to eliminate the need for insulation measures for the outer end surfaces of the flat conductive wires at the corners of the winding portion 12a.

Furthermore, in the above embodiment, the inner end surface of the rectangular conducting wire constituting the winding portion 12a is not covered with the insulating film 12b, but the present invention is not limited to this. For example, as shown in FIG. 14, an insulating film 12bD having a bent portion 12b2 may be used by bending the inner part of the insulating film 12bD so as to stand up. This bent portion 12b2 is bent so as to face the inner end surface of the rectangular conductive wire forming one of the first turn portion and the second turn portion, which are two adjacent turn portions in the winding portion 12a. By using the insulating film 12bD configured in this manner, it is possible to protect the inner edge portion of the rectangular conductive wire that constitutes the winding portion 12a.

Further, in the above embodiment, the plurality of insulating films 12b inserted into each turn of the winding portion 12a of the coil 12 are not connected, but the present invention is not limited to this. For example, the insulating film 12b inserted into each turn of the winding portion 12a of the coil 12 may be connected at a portion.

Furthermore, in the above embodiment, the winding portion 12a is formed by laminating a plurality of turn portions by winding a rectangular conducting wire by edgewise bending, but the present invention is not limited to this. For example, the winding portion 12a may be formed by laminating a plurality of turn portions by connecting a plurality of rectangular conducting wires.

Further, in the above embodiment, the number of slots in the stator 10 is 18, but the number is not limited to this. Similarly, in the above embodiment, the number of magnetic poles of the rotor 20 is 10 (that is, the number of permanent magnets 22 is 10), but the present invention is not limited to this. Any number of slots in the stator 10 and any number of magnetic poles in the rotor 20 can be used.

Further, in the above embodiment, the rotor 20 is an IPM rotor, but the rotor 20 is not limited to this. For example, when a permanent magnet type rotor is used as the rotor 20, a surface magnet type rotor (SPM rotor) in which a plurality of permanent magnets are provided on the outer surface of the rotor core may be used.

Further, in the above embodiment, the electric motor 1 is illustrated as an example of the rotating electric machine, but the present invention is not limited to this. For example, the rotating electric machine using the coil 12 may be a generator. Further, although the coil 12 is used as a wire-wound coil included in the stator 10, the coil 12 is not limited to this, and may be used as various coils included in products other than the stator.

Other embodiments may be obtained by making various modifications to the above embodiments by those skilled in the art, or by arbitrarily combining the components and functions of the above embodiments without departing from the spirit of the present disclosure. The present disclosure also includes forms in which: Further, the present disclosure also includes arbitrary combinations of one or more constituent elements in each of the plurality of claims recited in the claims as filed. In addition, when the dependent form claims stated in the scope of claims at the time of filing of the present application are made into multiple claims or multiple multi-claims so as to cite any plurality of claims (for example, the superordinate claim for each claim) When all claims are referred to as a multiple claim or multiple multiple claims), all forms obtained by combining all claims included in the multiple claim or multiple multiple claims are also included in the present disclosure.

The technology of the present disclosure can be widely used in various products using coils, including rotating electric machines such as electric motors.

1 Electric motor 10 Stator 11 Stator core 11a Teeth 11b

Yoke 11c Slot

12, 12A, 12B, 12C Coil 12a Winding portion 12b, 12bA, 12bB, 12bC, 12bD Insulating film 12b1 Notch portion 12b2 Bend portion 12M Flat conductor wire 13 Insulator 13a 1st Frame 13b Second frame 20 Rotor 21 Rotor core 22 Permanent magnet 23

Rotating shaft

100, 100B Coil block

Claims

A coil used in a rotating electric machine,
A winding part in which a plurality of turn parts are stacked by winding a flat conductor by edgewise bending or by connecting a plurality of flat conductors;
an annular insulating film inserted between a first turn part and a second turn part, which are two adjacent turn parts in the plurality of turn parts;
coil.
The insulating film is in contact with each of the main surface of the rectangular conductive wire forming the first turn portion and the main surface of the rectangular conducting wire forming the second turn portion,
The coil according to claim 1.
The insulating film is in contact with a portion of each of the main surface of the rectangular conducting wire forming the first turn portion and the main surface of the rectangular conducting wire forming the second turn portion,
An air layer is present in the gap between the main surface of the rectangular conducting wire constituting the first turn portion and the main surface of the rectangular conducting wire constituting the second turn portion, where the insulating film is not present.
The coil according to claim 2.
The width of the rectangular conducting wire constituting the first turn portion is different from the width of the rectangular conducting wire constituting the second turn portion,
The coil according to any one of claims 1 to 3.
The insulating film is provided for each turn of the winding portion,
The coil according to any one of claims 1 to 3.
The insulating film has a cutout portion through which a rectangular conductive wire forming each of the plurality of turn portions passes.
The coil according to claim 5.
the insulating film overlaps in the notch,
The coil according to claim 6.
The cutout portions are located at different positions in the two adjacent turn portions when viewed from the stacking method of the plurality of turn portions.
The coil according to claim 6.
Each of the plurality of insulating films has the same inner diameter,
The coil according to claim 5.
The plurality of insulating films have outer diameters gradually increasing.
The coil according to claim 9.
The insulating film is formed so as to protrude from each corner of at least the rectangular conducting wire constituting the first turn portion and the rectangular conducting wire constituting the second turn portion.
The coil according to any one of claims 1 to 3.
The insulating film has a bent portion that is bent to face an inner end surface of a rectangular conductive wire constituting one of the first turn portion and the second turn portion.
The coil according to any one of claims 1 to 3.
The outer end surface of the rectangular conducting wire constituting the winding portion is exposed;
The coil according to any one of claims 1 to 3.
The insulating film is an insulating tape having an adhesive layer,
the insulating film is fixed to the rectangular conductive wire by the adhesive layer;
The coil according to any one of claims 1 to 3.
The coil according to any one of claims 1 to 3, wherein the insulating film is fixed to the rectangular conductive wire with varnish.
a stator core having multiple teeth;
a winding coil wound around each of the plurality of teeth,
The wire-wound coil is the coil according to any one of claims 1 to 3,
stator.
an insulator interposed between the winding coil and the teeth,
The insulating film is not present in a portion of the wire-wound coil that is in contact with the insulator.
A stator according to claim 16.
A stator according to claim 16;
a rotor that rotates due to the magnetic force of the stator;
Rotating electric machine.