WO2024048294A1 - Stator and method for manufacturing stator - Google Patents

Stator and method for manufacturing stator Download PDF

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Publication number
WO2024048294A1
WO2024048294A1 PCT/JP2023/029686 JP2023029686W WO2024048294A1 WO 2024048294 A1 WO2024048294 A1 WO 2024048294A1 JP 2023029686 W JP2023029686 W JP 2023029686W WO 2024048294 A1 WO2024048294 A1 WO 2024048294A1
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WO
WIPO (PCT)
Prior art keywords
sides
portions
circumferential direction
slot
stator
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Application number
PCT/JP2023/029686
Other languages
French (fr)
Japanese (ja)
Inventor
周平 明上
Original Assignee
株式会社オートネットワーク技術研究所
住友電装株式会社
住友電気工業株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Application filed by 株式会社オートネットワーク技術研究所, 住友電装株式会社, 住友電気工業株式会社 filed Critical 株式会社オートネットワーク技術研究所
Publication of WO2024048294A1 publication Critical patent/WO2024048294A1/en

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—Stationary parts of the magnetic circuit
    • H02K1/16—Stator cores with slots for windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/32—Windings characterised by the shape, form or construction of the insulation
    • H02K3/34—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/48—Fastening of windings on the stator or rotor structure in slots

Definitions

  • the present disclosure relates to a stator and a method of manufacturing the stator.
  • Patent Document 1 discloses a molded motor including a stator.
  • the stator includes a stator core in which a plurality of salient poles are arranged in a circumferential direction, and a plurality of coils wound around each salient pole of the stator core via an insulator. The coil windings are passed through slots formed between the salient poles and wound around the salient poles.
  • One object of the present disclosure is to provide a technique that can suppress circumferential displacement of the insertion portion of a coil inserted into a slot.
  • the stators of this disclosure are: an annular stator core; A coil attached to the stator core,
  • the stator core has a plurality of slots arranged in parallel in the circumferential direction of the stator core, and overhanging portions extending from inner walls on both sides of the slot in the circumferential direction,
  • the coil has an insertion part that is inserted into the slot,
  • the insertion portion is arranged between the overhang portions on both sides in the circumferential direction, in contact with at least one of the overhang portions.
  • the method for manufacturing a stator of the present disclosure includes: a preparation step of preparing an annular stator core and a coil segment;
  • the stator core has a plurality of slots arranged in parallel in the circumferential direction of the stator core, and overhanging portions extending from inner walls on both sides of the slot in the circumferential direction,
  • the coil segment has an insertion portion that is inserted into the slot,
  • the method further includes an insertion step of inserting the insertion portion into the slot from one side in the axial direction of the stator core so that the insertion portion passes between the projecting portions on both sides in the circumferential direction.
  • the technology according to the present disclosure can suppress displacement of the insertion portion of the coil inserted into the slot in the circumferential direction.
  • FIG. 1 is a perspective view of the stator core of the first embodiment.
  • FIG. 2 is a cross-sectional view of the stator of the first embodiment taken at the center in the axial direction.
  • FIG. 3 is a plan view of the stator core of the first embodiment in a state where the projecting portion is not bent and deformed, and is a partially enlarged view of the vicinity of the slot.
  • FIG. 4 is an explanatory diagram showing the state before the coil segment is inserted into the slot.
  • FIG. 5 is an explanatory diagram showing a state in which a coil segment is inserted into a slot.
  • FIG. 6 is an explanatory diagram showing how the slot is filled with resin material.
  • FIG. 7 is a sectional view showing the structure inside the slot.
  • FIG. 1 is a perspective view of the stator core of the first embodiment.
  • FIG. 2 is a cross-sectional view of the stator of the first embodiment taken at the center in the axial direction.
  • FIG. 3 is a plan view of
  • FIG. 8 is a cross-sectional view of the stator of the second embodiment taken at the center in the axial direction.
  • FIG. 9 is a plan view of the stator core of the second embodiment in a state where the projecting portion is not bent and deformed, and is a partially enlarged view of the vicinity of the slot.
  • annular stator core A coil attached to the stator core,
  • the stator core has a plurality of slots arranged in parallel in the circumferential direction of the stator core, and overhanging portions extending from inner walls on both sides of the slot in the circumferential direction,
  • the coil has an insertion part that is inserted into the slot,
  • the said insertion part is arrange
  • the insertion portion is restricted from being displaced toward the overhang by the overhang that comes into contact with itself. Therefore, in the stator, the insertion portion of the coil inserted into the slot can be prevented from being displaced in the circumferential direction.
  • the displacement of the insertion portion on both sides in the circumferential direction is regulated by the overhanging portions on both sides in the circumferential direction. Therefore, the stator can suppress displacement of the insertion portion to both sides in the circumferential direction.
  • a plurality of the insertion portions are arranged in the slot in a radial direction of the stator core, The projecting portions on both sides in the circumferential direction are interposed between each of the insertion portions and the inner walls on both sides in the circumferential direction, and are continuous in the direction in which the plurality of insertion portions are lined up. [1] or [2] ] The stator described in ].
  • the gap between the inner wall of the slot and each insertion portion can be continuously closed by the overhang portion in the direction in which the plurality of insertion portions are lined up.
  • a plurality of the insertion portions are arranged in the slot in a radial direction of the stator core,
  • the projecting portions on both sides in the circumferential direction have individual projecting portions provided corresponding to each of the insertion portions, [1] or [Each of the individual projecting portions is arranged such that at least one of the individual projecting portions on both sides in the circumferential direction is in contact with the corresponding insertion portion. 2].
  • the above-mentioned stator can individually suppress displacement of each insertion portion in the circumferential direction by the individual projecting portions provided corresponding to each insertion portion.
  • At least one of the protruding parts on both sides in the circumferential direction that contacts the insertion part is bent and deformed by being pressed by the insertion part, and the curved convex surface is curved.
  • the displacement of the stator on both sides in the circumferential direction is more firmly regulated by the reaction force from the at least one protrusion. Therefore, the stator can more reliably suppress displacement of the insertion portion to both sides in the circumferential direction.
  • the insertion part has a conductor part and a covering part that covers the outer periphery of the conductor part,
  • the covering part may be damaged due to the overhanging part coming into contact with the covering part. Since the stator is arranged with the convex surface of the overhanging portion in contact with the surface of the covering portion, damage to the covering portion due to contact of the overhanging portion with the covering portion can be suppressed.
  • the stator core has an annular yoke portion and a plurality of teeth portions arranged annularly along the yoke portion, Each of the slots is divided into the yoke portion and the two adjacent teeth portions, The yoke portion and the plurality of teeth portions are integrally formed by laminating a plurality of electromagnetic steel plates in the axial direction of the stator core, The stator according to any one of [1] to [6], wherein the projecting portion is integrally formed with the teeth portion from the electromagnetic steel plate.
  • the overhanging portion is formed integrally with the tooth portion using the electromagnetic steel sheet that constitutes the yoke portion and the teeth portion, so the overhanging portion can be formed while suppressing an increase in the number of parts.
  • the projecting portions are provided on both sides within the slot in the axial direction of the stator core, Any one of [1] to [7], wherein the insertion portion is arranged on both sides of the slot in the axial direction so as to be in contact with at least one of the projecting portions on both sides in the circumferential direction. Stator described in Crab.
  • the insertion portion is regulated from being displaced toward the overhang by the overhang that comes into contact with itself on both sides in the axial direction within the slot. Therefore, in the stator, displacement of the insertion portion in the circumferential direction can be suppressed on both sides of the slot in the axial direction.
  • an insulating resin filled in the slot According to [8], the insulating resin has a continuous filling part that is continuously filled between the inner walls on both sides in the circumferential direction and the insertion part between the overhang parts on both sides in the axial direction. stator.
  • [10] Includes a preparation step of preparing an annular stator core and coil segments,
  • the stator core has a plurality of slots arranged in parallel in the circumferential direction of the stator core, and overhanging portions extending from inner walls on both sides of the slot in the circumferential direction,
  • the coil segment has an insertion portion that is inserted into the slot,
  • the method for manufacturing a stator further includes an insertion step of inserting the insertion portion into the slot from one side in the axial direction of the stator core so that the insertion portion passes between the overhang portions on both sides in the circumferential direction.
  • the projecting portion is disposed on both sides of the slot in the axial direction, and can be flexibly deformed about a portion supported by the inner wall as a fulcrum;
  • the distance between the projecting portions on both sides in the circumferential direction in a state where they are not bent and deformed is smaller than the width of the insertion portion,
  • the insertion portion is inserted into the slot from one side in the axial direction so that the insertion portion passes between the projecting portions on both sides in the circumferential direction on both sides in the axial direction within the slot.
  • stator manufacturing method it is possible to fill the slots with the resin material while suppressing leakage of the resin material by the overhangs on both sides in the axial direction.
  • a plurality of the insertion portions are arranged in the slot in a radial direction of the stator core, The projecting portions on both sides in the circumferential direction are interposed between each of the insertion portions and the inner wall, and are continuous in the direction in which the plurality of insertion portions are lined up;
  • the resin material is placed between the overhangs on both sides in the axial direction, with each of the insertion portions being disposed between the overhangs on both sides in the circumferential direction on both sides in the axial direction.
  • the gap between each insertion portion and the inner wall is continuously covered by the overhang portions on both sides in the axial direction in the direction in which the plurality of insertion portions are lined up, and the resin material is filled in the slot. Can be filled.
  • the stator 1 of the first embodiment is used as a component of a rotating electric machine (specifically, a motor).
  • the stator 1 has an annular shape, more specifically an annular shape.
  • the stator 1 includes a stator core 10, a coil 30, and an insulating resin 40, as shown in FIGS. 2 and 7.
  • the stator core 10 has an annular shape, more specifically an annular shape.
  • the radial direction of stator core 10 will be referred to as the radial direction
  • the axial direction of stator core 10 will be referred to as the axial direction
  • the circumferential direction of stator core 10 will be referred to as the circumferential direction. Note that in FIG. 1, the overhanging portions 21 and 22 (see FIG. 7) are omitted.
  • the stator core 10 includes a yoke portion 11 and a plurality of teeth portions 12.
  • the yoke portion 11 has an annular shape, more specifically an annular shape.
  • the plurality of teeth portions 12 are arranged in a ring shape along the inner circumferential surface of the yoke portion 11 .
  • the respective teeth portions 12 are arranged at intervals from each other in the circumferential direction.
  • Each tooth portion 12 projects radially inward from the inner peripheral portion of the yoke portion 11 .
  • Each tooth portion 12 has a wall shape along the radial direction and the axial direction.
  • Each tooth portion 12 includes a tooth main body 13 having a wall shape along the radial direction and the axial direction, and a tooth tension extending from the distal end portion (in other words, the inner end portion in the radial direction) of the tooth main body 13 to both sides in the circumferential direction. It has an exit part 14.
  • the yoke portion 11 and the plurality of teeth portions 12 are integrally formed by laminating a plurality of electromagnetic steel plates (for example, silicon steel plates) in the axial direction of the stator core 10.
  • the stator core 10 has a plurality of slots 15, as shown in FIG.
  • the plurality of slots 15 are arranged side by side in the circumferential direction and form an annular shape. Slot 15 passes through stator core 10 in the axial direction.
  • the slot 15 has a first opening 16, a second opening 17, and a third opening 18, as shown in FIGS. 2 and 7.
  • the first opening 16 is formed on one surface of the stator core 10 in the axial direction.
  • the second opening 17 is formed on the other axial surface of the stator core 10 .
  • the third opening 18 is formed on the radially inner surface of the stator core 10.
  • the third opening 18 is continuous with the first opening 16 and the second opening 17.
  • each slot 15 is divided into a yoke portion 11 and two adjacent teeth portions 12.
  • the stator core 10 has projecting portions 21 and 22 projecting from the inner walls of the slot 15 on both sides in the circumferential direction.
  • the projecting portions 21 and 22 are supported in a cantilever manner by the inner wall of the slot 15, and can be deformed by using the portion supported by the inner wall as a fulcrum.
  • the projecting portions 21 and 22 are provided on both sides of the slot 15 in the axial direction.
  • An overhang 21 , 22 is provided within each slot 15 .
  • the overhanging portions 21 and 22 are integrally formed with the tooth portion 12 using an electromagnetic steel plate that forms the tooth portion 12. According to this configuration, the stator core 10 can form the projecting portions 21 and 22 while suppressing an increase in the number of parts.
  • the coil 30 is attached to the stator core 10.
  • Coil 30 is wound around stator core 10 (more specifically, teeth portion 12).
  • the coil 30 may have distributed winding or concentrated winding. When the coil 30 is distributed winding, it may be wave winding, concentric winding, or lap winding. In this embodiment, the coil 30 will be described as a wave-wound coil.
  • the coil 30 passes through the slot 15 and is wound around the teeth portion 12 .
  • the coil 30 is constructed using a covered electric wire in which the outer periphery of a core wire is covered with a coating.
  • the coil 30 is a flat wire in this embodiment. Note that the coil 30 does not need to be a rectangular wire, and may be a round wire, for example. As shown in FIG. 2, the coil 30 has a rectangular cross section cut in a direction perpendicular to the length direction of the coil 30.
  • the coil 30 has an insertion portion 31 that is inserted into the slot 15.
  • the insertion portion 31 is constructed using a covered electric wire.
  • the insertion portion 31 is inserted into the slot 15 in the axial direction.
  • the insertion portion 31 has a linear shape.
  • One end of the insertion portion 31 protrudes toward one axial side from the end of the slot 15 on one axial side (that is, the first opening 16).
  • the other end of the insertion portion 31 protrudes from the other axial end of the slot 15 (that is, the second opening 17) toward the other axial side.
  • the insertion portion 31 is constructed using a flat wire. As shown in FIG. 2, the insertion portion 31 has a rectangular cross section cut in a direction perpendicular to the length direction (axial direction) of the insertion portion 31.
  • the coil 30 is constructed using a covered electric wire in which the outer periphery of a core wire is covered with a coating.
  • the insertion portion 31 includes a conductor portion 32 and a covering portion 33 that covers the outer periphery of the conductor portion 32.
  • the conductor portion 32 has electrical conductivity.
  • the conductor portion 32 is constructed using a core wire of a covered electric wire. As shown in FIG. 7, the conductor portion 32 has a linearly extending form. The conductor portion 32 extends in the axial direction. As shown in FIG. 2, the conductor portion 32 has a rectangular cross section cut in a direction perpendicular to the length direction of the conductor portion 32.
  • the covering portion 33 has insulation properties.
  • the covering portion 33 is configured using a covering of a covered electric wire.
  • the material of the covering portion 33 is not particularly limited.
  • the covering portion 33 is a low dielectric constant enamel having a low dielectric constant.
  • the covering portion 33 is mainly made of a thermosetting resin such as polyvinyl formal, thermosetting polyurethane, thermosetting acrylic, epoxy, thermosetting polyester, thermosetting polyesterimide, aromatic polyamide, thermosetting polyamideimide, thermosetting polyimide, etc. Good too.
  • the covering portion may be mainly composed of a thermoplastic resin such as polyetherimide, polyphenylene ether, polyether sulfone, polyphenylene sulfide, polyether ether ketone, or thermoplastic polyimide.
  • the "main component" is the component with the highest content, for example, 50% by mass or more.
  • the insulating resin 40 is filled in the slot 15 like the slot 15B shown in FIG.
  • the insulating resin 40 has a continuous filling portion 41 that is continuously filled between the inner wall of the slot 15 and the insertion portion 31 in the axial center of the stator core 10 .
  • the continuous filling portion 41 is continuously filled between the projecting portions 21 and 22 on both sides in the axial direction within the slot 15 .
  • the above-mentioned insertion portion 31 is arranged between the projecting portions 21 and 22 on both sides in the circumferential direction.
  • the insertion portion 31 is arranged in contact with both of the projecting portions 21 and 22 on both sides in the circumferential direction. According to this configuration, displacement of the insertion portion 31 on both sides in the circumferential direction is regulated by the projecting portions 21 and 22 on both sides in the circumferential direction. Therefore, the stator 1 can suppress displacement of the insertion portion 31 to both sides in the circumferential direction.
  • the insertion portion 31 is arranged on both sides in the axial direction with the overhangs 21 and 22 on both sides in the circumferential direction in contact with the overhangs 21 and 22. According to this configuration, displacement of the insertion portion 31 toward the overhang portions 21 and 22 is regulated by the overhang portions 21 and 22 that come into contact with the insertion portion 31 on both sides of the slot 15 in the axial direction. Therefore, the stator 1 can suppress displacement of the insertion portion 31 in the circumferential direction on both sides of the slot 15 in the axial direction.
  • a plurality of (four in this embodiment) insertion portions 31 are arranged in the slot 15 in a line in the radial direction.
  • the insulating resin 40 is omitted in the slot 15A
  • the slot 15B is shown filled with the insulating resin 40.
  • the projecting portions 21 and 22 on both sides in the circumferential direction are interposed between each insertion portion 31 and the inner wall on both sides in the circumferential direction of the slot 15, and are continuous in the direction in which the plurality of insertion portions 31 are lined up.
  • the stator 1 continuously closes the gap between the inner wall on both sides of the slot 15 in the circumferential direction and each insertion portion 31 in the direction in which the plurality of insertion portions are lined up by the overhanging portions 21 and 22. be able to.
  • the radial length of the overhanging portions 21 and 22 is the “radial length of the insertion portion 31 (width of the insertion portion 31)” and “the length of the plurality of insertion portions 31 arranged in the radial direction within the slot 15.” greater than the value multiplied by "number”.
  • the radially inner end portions of the overhanging portions 21 and 22 are arranged radially inner than the insertion portion 31 which is arranged radially innermost.
  • the radially outer end portions of the projecting portions 21 and 22 are arranged radially outer than the insertion portion 31 which is disposed most radially outwardly.
  • the projecting portions 21 and 22 on both sides in the circumferential direction that contact the insertion portion 31 are both bent and deformed by being pressed by the insertion portion 31.
  • the curved convex surfaces 21A and 22A of the projecting parts 21 and 22 are arranged in contact with the insertion part 31.
  • the curved convex surfaces 21A and 22A of the projecting parts 21 and 22 are arranged in contact with the insertion part 31 on both sides in the axial direction.
  • the convex surfaces 21A and 22A of the projecting parts 21 and 22 are arranged in contact with the surface of the covering part 33.
  • the covering portion 33 may be damaged due to the protruding portions 21 and 22 coming into contact with the covering portion 33. Since the stator 1 is arranged with the convex surfaces 21A and 22A of the overhanging parts 21 and 22 in contact with the surface of the covering part 33, the overhanging parts 21 and 22 contact the covering part 33, causing the covering part 33 to Damage can be suppressed.
  • the entire overhangs 21 and 22 on one side in the axial direction are arranged within the slot 15, and the overhangs 21 and 22 on the other side in the axial direction project outside the slot 15.
  • the entire overhangs 21 and 22 on both sides in the axial direction may be disposed within the slot 15, or the overhangs 21 and 22 on both sides in the axial direction may extend outside the slot 15.
  • the method for manufacturing stator 1 includes a preparation process, an insertion process, a filling process, a bending process, and a welding process.
  • the stator core 10 and coil segments 50 described above are prepared.
  • the protruding parts 21 and 22 of the stator core 10 have a rectangular shape that is elongated in the radial direction in a state in which they are not flexibly deformed.
  • the spacing GA between the projecting portions 21 and 22 on both sides in the circumferential direction in a state where the projecting portions 21 and 22 are not bent is smaller than the width of the insertion portion 31 .
  • the width of the insertion portion 31 (more specifically, the width of the insertion portion 31 in the direction perpendicular to the axial direction and perpendicular to the direction in which the plurality of insertion portions 31 are arranged) is the width between the inner walls on both sides of the slot 15 in the circumferential direction. is smaller than the spacing GB, and larger than the spacing GA between the projecting portions 21 and 22 on both sides in the circumferential direction in a state where they are not flexibly deformed.
  • the coil segment 50 is, for example, U-shaped and has two insertion portions 31 .
  • the insertion portion 31 is inserted into the slot 15 from one side in the axial direction of the stator core 10 so that the insertion portion 31 passes between the projecting portions 21 and 22 on both sides in the circumferential direction. Insert it through.
  • this method when the insertion portion 31 is inserted into the slot 15, displacement of the insertion portion 31 to both sides in the circumferential direction is restricted by the overhang portions 21 and 22 on both sides. Further, even when the insertion portion 31 is disposed within the slot 15, displacement of the insertion portion 31 to both sides in the circumferential direction is restricted by the overhang portions 21 and 22 on both sides in the circumferential direction. That is, according to this method, displacement of the insertion portion 31 of the coil segment 50 that constitutes the coil 30 in the circumferential direction can be suppressed.
  • the insertion portion 31 In the insertion step, when the insertion portion 31 is inserted into the slot 15, the insertion portion 31 is inserted between the overhang portions 21 and 22 while bending and deforming the overhang portions 21 and 22 on both sides in the circumferential direction. Pass. According to this method, the insertion portion 31 is moved toward the center of the slot 15 in the circumferential direction by the projecting portions 21 and 22 on both sides in the circumferential direction. Therefore, it is possible to prevent the covering portion 33 of the insertion portion 31 from coming into contact with the open end of the slot 15 and being damaged.
  • the insertion portion 31 is inserted into the slot 15 from one side in the axial direction so that the insertion portion 31 passes between the protruding portions 21 and 22 on both sides in the circumferential direction on both sides of the slot 15 in the axial direction. Thereby, the gap between the inner wall of the slot 15 on both sides in the circumferential direction and the insertion portion 31 can be closed on both sides in the axial direction within the slot 15.
  • the two insertion portions 31 of the coil segment 50 are inserted into separate slots 15, respectively.
  • Four insertion portions 31 are inserted into each slot 15 .
  • the overhangs 21 on both sides in the axial direction , 22 is filled with a resin material 61.
  • the resin material 61 can be filled into the slot 15 while suppressing leakage of the resin material 61 by the overhangs 21 and 22 on both sides in the axial direction.
  • the resin material 61 is cured, it becomes the insulating resin 40.
  • the projecting portions 21 and 22 on both sides in the circumferential direction are interposed between each insertion portion 31 and the inner wall on both sides in the circumferential direction of the slot 15, and are continuous in the direction in which the plurality of insertion portions 31 are lined up. For this reason, the gap between each insertion portion 31 and the inner wall on both sides in the circumferential direction is continuously covered by the overhang portions 21 and 22 on both sides in the axial direction in the direction in which the plurality of insertion portions 31 are lined up, and the inside of the slot 15 is can be filled with resin material 61.
  • a filling device 60 that discharges the resin material 61 is placed in the inner space of the annular stator core 10. Then, the filling device 60 covers the radially inner opening (third opening 18) of the slot 15, except for the injection port 62 for the resin material 61, with a cover 63 of the filling device 60.
  • the injection port 62 for the resin material 61 is arranged between the protrusions 21 and 22 on both sides in the axial direction.
  • the filling device 60 fills the resin material 61 between the projecting portions 21 and 22 on both sides in the axial direction by filling the resin material 61 from the injection port 62 .
  • the filling of the resin material 61 may be performed by intermittently rotating the filling device 60 to fill each slot 15 in turn, or by filling all the slots 15 at once. .
  • the stator 1 is completed as shown in FIG.
  • the stator 201 shown in FIG. 8 includes a stator core 210, a coil 30, and an insulating resin 40.
  • Stator core 210 has a yoke portion 11, a plurality of teeth portions 12, and a plurality of slots 15.
  • Stator core 210 has projecting portions 221 and 222 projecting from inner walls on both circumferential sides of slot 15 .
  • a plurality of insertion portions 31 are arranged in the slot 15 in a line in the radial direction of the stator core 210.
  • the projecting portions 221 and 222 on both sides in the circumferential direction have individual projecting portions 223 and 224 provided corresponding to each insertion portion 31 individually.
  • the individual projecting portions 223 and 224 on both sides in the circumferential direction are arranged in contact with the corresponding insertion portions 31, respectively. According to this configuration, the stator 201 can individually suppress displacement of each insertion portion 31 to both sides in the circumferential direction by the individual projecting portions 223 and 224 provided correspondingly to each insertion portion 31. Can be done.
  • the method of manufacturing the stator 201 is the same as the method of manufacturing the stator 1 of the first embodiment, but the following differences occur due to the difference in configuration.
  • Each of the individual protruding parts 223 and 224 is arranged between the corresponding insertion part 31 and the inner walls on both sides in the circumferential direction within the slot 15, and is bent independently of each other using the parts supported by the inner walls as fulcrums. Deformable. As shown in FIG. 9, the individual projecting portions 223 and 224 have a radially long rectangular shape in a state in which they are not bent or deformed. In a state where the individual projecting portions 223 and 224 are not flexibly deformed, the distance GC between the individual projecting portions 223 and 224 on both sides in the circumferential direction is smaller than the width of the insertion portion 31.
  • the width of the insertion portion 31 (more specifically, the width of the insertion portion 31 in the direction perpendicular to the axial direction and perpendicular to the direction in which the plurality of insertion portions 31 are arranged) is the width between the inner walls on both sides of the slot 15 in the circumferential direction. is smaller than the spacing GB, and larger than the spacing GC between the individual projecting portions 223 and 224 on both sides in the circumferential direction in a state where they are not flexibly deformed.
  • each of the individual projecting portions 223 and 224 is individually displaced according to the position of the corresponding insertion portion 31, so that the respective projecting portions 221 and 222 and the insertion portion 31 are displaced in the circumferential direction. There will be fewer gaps between them.
  • the overhang portion and the teeth portion are integrally formed of the same member, but the overhang portion may be formed of a separate member from the teeth portion.
  • the insertion portion was configured to contact both of the protruding portions on both sides in the circumferential direction, but may be configured to contact only one side.
  • the overhanging portions on both sides in the circumferential direction are both bent and curved, but only one of the overhanging portions on both sides in the circumferential direction is bent and bent. Alternatively, neither of them may be curved.
  • the convex surface of the overhanging portion is in contact with the insertion portion, but the overhanging end of the overhanging portion may be in contact with the insertion portion.

Abstract

A stator (1) comprises: an annular stator core (10); and a coil (30) attached to the stator core (10). The stator core (10) includes: a plurality of slots (15) that are arranged in a row in the circumferential direction of the stator core (10); and projecting parts (21, 22) that project from inner walls on both sides of a slot (15) in the circumferential direction. The coil (30) includes an insertion part (31) to be inserted into the slot (15). The insertion part (31) is arranged between the projecting parts (21, 22) on both sides in the circumferential direction, in contact with at least one of the projecting parts (21, 22).

Description

ステータ、及びステータの製造方法Stator and stator manufacturing method
　本開示は、ステータ、及びステータの製造方法に関する。 The present disclosure relates to a stator and a method of manufacturing the stator.
　特許文献１には、ステータを備えるモールドモータが開示されている。上記ステータは、複数の突極が周方向に並ぶステータコアと、ステータコアの突極ごとにインシュレータを介して巻回された複数のコイルと、を有する。コイルの巻線は、突極間に形成されたスロット内に通され、突極に巻回される。 Patent Document 1 discloses a molded motor including a stator. The stator includes a stator core in which a plurality of salient poles are arranged in a circumferential direction, and a plurality of coils wound around each salient pole of the stator core via an insulator. The coil windings are passed through slots formed between the salient poles and wound around the salient poles.
国際公開第２０１９／２２０９５６号International Publication No. 2019/220956
　特許文献１のように、コイルがスロット内に挿し通される挿通部を有する構成においては、挿通部がスロット内で周方向に変位しないことが望ましく、この点で改善の余地がある。 In a structure having an insertion part through which the coil is inserted into the slot, as in Patent Document 1, it is desirable that the insertion part not be displaced in the circumferential direction within the slot, and there is room for improvement in this respect.
　本開示は、スロット内に挿し通されるコイルの挿通部が周方向に変位することを抑えることが可能な技術を提供することを目的の一つとする。 One object of the present disclosure is to provide a technique that can suppress circumferential displacement of the insertion portion of a coil inserted into a slot.
　本開示のステータは、
　環状のステータコアと、
　前記ステータコアに装着されるコイルと、を備え、
　前記ステータコアは、前記ステータコアの周方向に並んで配置される複数のスロットと、前記スロットにおける前記周方向両側の内壁から張り出した張出部と、を有し、
　前記コイルは、前記スロット内に挿し通される挿通部を有し、
　前記挿通部は、前記周方向両側の前記張出部の間において、少なくとも一方の前記張出部に接触した状態で配置される。 The stators of this disclosure are:
an annular stator core;
A coil attached to the stator core,
The stator core has a plurality of slots arranged in parallel in the circumferential direction of the stator core, and overhanging portions extending from inner walls on both sides of the slot in the circumferential direction,
The coil has an insertion part that is inserted into the slot,
The insertion portion is arranged between the overhang portions on both sides in the circumferential direction, in contact with at least one of the overhang portions.
　本開示のステータの製造方法は、
　環状のステータコアとコイルセグメントとを準備する準備工程を含み、
　前記ステータコアは、前記ステータコアの周方向に並んで配置される複数のスロットと、前記スロットにおける前記周方向両側の内壁から張り出した張出部と、を有し、
　前記コイルセグメントは、前記スロット内に挿し通される挿通部を有し、
　更に、前記周方向両側の前記張出部の間に前記挿通部が通るように、前記ステータコアの軸方向一方側から前記挿通部を前記スロット内に挿し通す挿通工程を含む。 The method for manufacturing a stator of the present disclosure includes:
a preparation step of preparing an annular stator core and a coil segment;
The stator core has a plurality of slots arranged in parallel in the circumferential direction of the stator core, and overhanging portions extending from inner walls on both sides of the slot in the circumferential direction,
The coil segment has an insertion portion that is inserted into the slot,
Furthermore, the method further includes an insertion step of inserting the insertion portion into the slot from one side in the axial direction of the stator core so that the insertion portion passes between the projecting portions on both sides in the circumferential direction.
　本開示に係る技術は、スロット内に挿し通されるコイルの挿通部が周方向に変位することを抑えることができる。 The technology according to the present disclosure can suppress displacement of the insertion portion of the coil inserted into the slot in the circumferential direction.
図１は、第１実施形態のステータコアの斜視図である。FIG. 1 is a perspective view of the stator core of the first embodiment. 図２は、第１実施形態のステータを軸方向中央部で切断した断面図である。FIG. 2 is a cross-sectional view of the stator of the first embodiment taken at the center in the axial direction. 図３は、張出部が撓み変形していない状態の第１実施形態のステータコアの平面図であり、スロット周辺の部分拡大図である。FIG. 3 is a plan view of the stator core of the first embodiment in a state where the projecting portion is not bent and deformed, and is a partially enlarged view of the vicinity of the slot. 図４は、スロット内にコイルセグメントを挿し通す前の状態をあらわす説明図である。FIG. 4 is an explanatory diagram showing the state before the coil segment is inserted into the slot. 図５は、スロット内にコイルセグメントを挿し通した状態をあらわす説明図である。FIG. 5 is an explanatory diagram showing a state in which a coil segment is inserted into a slot. 図６は、スロット内に樹脂材料を充填する様子をあらわす説明図である。FIG. 6 is an explanatory diagram showing how the slot is filled with resin material. 図７は、スロット内の構造をあらわす断面図である。FIG. 7 is a sectional view showing the structure inside the slot. 図８は、第２実施形態のステータを軸方向中央で切断した断面図である。FIG. 8 is a cross-sectional view of the stator of the second embodiment taken at the center in the axial direction. 図９は、張出部が撓み変形していない状態の第２実施形態のステータコアの平面図であり、スロット周辺の部分拡大図である。FIG. 9 is a plan view of the stator core of the second embodiment in a state where the projecting portion is not bent and deformed, and is a partially enlarged view of the vicinity of the slot.
　以下では、本開示の実施形態が列記されて例示される。 Below, embodiments of the present disclosure are listed and illustrated.
　〔１〕環状のステータコアと、
　前記ステータコアに装着されるコイルと、を備え、
　前記ステータコアは、前記ステータコアの周方向に並んで配置される複数のスロットと、前記スロットにおける前記周方向両側の内壁から張り出した張出部と、を有し、
　前記コイルは、前記スロット内に挿し通される挿通部を有し、
　前記挿通部は、前記周方向両側の前記張出部の間において、少なくとも一方の前記張出部に接触した状態で配置される
　ステータ。 [1] Annular stator core,
A coil attached to the stator core,
The stator core has a plurality of slots arranged in parallel in the circumferential direction of the stator core, and overhanging portions extending from inner walls on both sides of the slot in the circumferential direction,
The coil has an insertion part that is inserted into the slot,
The said insertion part is arrange|positioned between the said overhang parts on both sides of the said circumferential direction in the state which contacted at least one said overhang part. Stator.
　挿通部は、自身に接触する張出部によって、当該張出部側への変位が規制される。したがって、上記ステータは、スロット内に挿し通されるコイルの挿通部が周方向に変位することを抑えることができる。 The insertion portion is restricted from being displaced toward the overhang by the overhang that comes into contact with itself. Therefore, in the stator, the insertion portion of the coil inserted into the slot can be prevented from being displaced in the circumferential direction.
　〔２〕前記挿通部は、前記周方向両側の前記張出部に接触した状態で配置される
　〔１〕に記載のステータ。 [2] The stator according to [1], wherein the insertion portion is arranged in contact with the projecting portions on both sides in the circumferential direction.
　挿通部は、周方向両側の張出部によって、周方向両側の変位が規制される。したがって、上記ステータは、挿通部の周方向両側への変位を抑えることができる。 The displacement of the insertion portion on both sides in the circumferential direction is regulated by the overhanging portions on both sides in the circumferential direction. Therefore, the stator can suppress displacement of the insertion portion to both sides in the circumferential direction.
　〔３〕前記スロット内には、複数の前記挿通部が前記ステータコアの径方向に並んで配置され、
　前記周方向両側の前記張出部は、各々の前記挿通部と前記周方向両側の前記内壁との間に介在し、複数の前記挿通部が並ぶ方向に連続している
　〔１〕又は〔２〕に記載のステータ。 [3] A plurality of the insertion portions are arranged in the slot in a radial direction of the stator core,
The projecting portions on both sides in the circumferential direction are interposed between each of the insertion portions and the inner walls on both sides in the circumferential direction, and are continuous in the direction in which the plurality of insertion portions are lined up. [1] or [2] ] The stator described in ].
　上記ステータは、スロットの内壁と各々の挿通部との間の隙間を、張出部によって複数の挿通部が並ぶ方向に連続して塞ぐことができる。 In the stator, the gap between the inner wall of the slot and each insertion portion can be continuously closed by the overhang portion in the direction in which the plurality of insertion portions are lined up.
　〔４〕前記スロット内には、複数の前記挿通部が前記ステータコアの径方向に並んで配置され、
　前記周方向両側の前記張出部は、各々の前記挿通部に個別に対応して設けられる個別張出部を有し、
　各々の前記個別張出部は、前記周方向両側の前記個別張出部のうち少なくとも片方の前記個別張出部が自身に対応する前記挿通部に接触した状態で配置される
　〔１〕又は〔２〕に記載のステータ。 [4] A plurality of the insertion portions are arranged in the slot in a radial direction of the stator core,
The projecting portions on both sides in the circumferential direction have individual projecting portions provided corresponding to each of the insertion portions,
[1] or [Each of the individual projecting portions is arranged such that at least one of the individual projecting portions on both sides in the circumferential direction is in contact with the corresponding insertion portion. 2].
　上記ステータは、各々の挿通部に個別に対応して設けられる個別張出部によって、各々の挿通部が周方向に変位することを個別に抑えることができる。 The above-mentioned stator can individually suppress displacement of each insertion portion in the circumferential direction by the individual projecting portions provided corresponding to each insertion portion.
　〔５〕前記挿通部に接触する前記周方向両側の前記張出部のうち少なくとも片方の前記張出部は、前記挿通部に押圧されて撓み変形して湾曲しており、湾曲した凸面が前記挿通部に接触した状態で配置される
　〔２〕に記載のステータ。 [5] At least one of the protruding parts on both sides in the circumferential direction that contacts the insertion part is bent and deformed by being pressed by the insertion part, and the curved convex surface is curved. The stator according to [2], which is arranged in contact with the insertion portion.
　上記ステータは、上記少なくとも片方の張出部からの反力によって、周方向両側の変位がより強固に規制される。したがって、上記ステータは、挿通部の周方向両側への変位をより確実に抑えることができる。 The displacement of the stator on both sides in the circumferential direction is more firmly regulated by the reaction force from the at least one protrusion. Therefore, the stator can more reliably suppress displacement of the insertion portion to both sides in the circumferential direction.
　〔６〕前記挿通部は、導体部と、前記導体部の外周を覆う被覆部と、を有し、
　前記凸面は、前記被覆部の表面に接触した状態で配置される
　〔５〕に記載のステータ。 [6] The insertion part has a conductor part and a covering part that covers the outer periphery of the conductor part,
The stator according to [5], wherein the convex surface is arranged in contact with the surface of the covering section.
　挿通部が被覆部を有する構成においては、張出部が被覆部に接触することによる被覆部の損傷が懸念される。上記ステータは、張出部の凸面が被覆部の表面に接触した状態で配置されるため、張出部が被覆部に接触することによる被覆部の損傷を抑えることができる。 In a configuration where the insertion part has a covering part, there is a concern that the covering part may be damaged due to the overhanging part coming into contact with the covering part. Since the stator is arranged with the convex surface of the overhanging portion in contact with the surface of the covering portion, damage to the covering portion due to contact of the overhanging portion with the covering portion can be suppressed.
　〔７〕前記ステータコアは、環状のヨーク部と、前記ヨーク部に沿って環状に並ぶ複数のティース部と、を有し、
　各々の前記スロットは、前記ヨーク部と隣り合う２つの前記ティース部とに区画されて形成され、
　前記ヨーク部、及び複数の前記ティース部は、複数の電磁鋼板を前記ステータコアの軸方向に積層して一体に形成され、
　前記張出部は、前記電磁鋼板によって前記ティース部と一体に形成されている
　〔１〕から〔６〕のいずれかに記載のステータ。 [7] The stator core has an annular yoke portion and a plurality of teeth portions arranged annularly along the yoke portion,
Each of the slots is divided into the yoke portion and the two adjacent teeth portions,
The yoke portion and the plurality of teeth portions are integrally formed by laminating a plurality of electromagnetic steel plates in the axial direction of the stator core,
The stator according to any one of [1] to [6], wherein the projecting portion is integrally formed with the teeth portion from the electromagnetic steel plate.
　上記ステータコアは、張出部が、ヨーク部及びティース部を構成する電磁鋼板によってティース部と一体に形成されるため、部品点数の増加を抑えた形で張出部を形成することができる。 In the stator core, the overhanging portion is formed integrally with the tooth portion using the electromagnetic steel sheet that constitutes the yoke portion and the teeth portion, so the overhanging portion can be formed while suppressing an increase in the number of parts.
　〔８〕前記張出部は、前記ステータコアの軸方向において前記スロット内の両側に設けられ、
　前記挿通部は、前記スロット内の前記軸方向両側において、前記周方向両側の前記張出部のうち少なくとも一方の前記張出部に接触した状態で配置される
　〔１〕から〔７〕のいずれかに記載のステータ。 [8] The projecting portions are provided on both sides within the slot in the axial direction of the stator core,
Any one of [1] to [7], wherein the insertion portion is arranged on both sides of the slot in the axial direction so as to be in contact with at least one of the projecting portions on both sides in the circumferential direction. Stator described in Crab.
　挿通部は、スロット内の軸方向両側において、自身に接触する張出部によって、当該張出部側への変位が規制される。したがって、上記ステータは、スロット内の軸方向両側において、挿通部が周方向に変位することを抑えることができる。 The insertion portion is regulated from being displaced toward the overhang by the overhang that comes into contact with itself on both sides in the axial direction within the slot. Therefore, in the stator, displacement of the insertion portion in the circumferential direction can be suppressed on both sides of the slot in the axial direction.
　〔９〕更に、前記スロット内に充填される絶縁樹脂を備え、
　前記絶縁樹脂は、前記軸方向両側の前記張出部の間において、前記周方向両側の前記内壁と前記挿通部との間で連続的に充填される連続充填部を有する
　〔８〕に記載のステータ。 [9] Further, an insulating resin filled in the slot,
According to [8], the insulating resin has a continuous filling part that is continuously filled between the inner walls on both sides in the circumferential direction and the insertion part between the overhang parts on both sides in the axial direction. stator.
　上記ステータは、連続充填部においてスロットの内壁と挿通部との間に絶縁紙が介在しないため、挿通部の熱が絶縁樹脂を介してステータコアに伝達されやすく、コイルの熱を放出しやすい。 In the above stator, since no insulating paper is interposed between the inner wall of the slot and the insertion part in the continuous filling part, the heat of the insertion part is easily transmitted to the stator core via the insulating resin, and the heat of the coil is easily released.
　〔１０〕環状のステータコアとコイルセグメントとを準備する準備工程を含み、
　前記ステータコアは、前記ステータコアの周方向に並んで配置される複数のスロットと、前記スロットにおける前記周方向両側の内壁から張り出した張出部と、を有し、
　前記コイルセグメントは、前記スロット内に挿し通される挿通部を有し、
　更に、前記周方向両側の前記張出部の間に前記挿通部が通るように、前記ステータコアの軸方向一方側から前記挿通部を前記スロット内に挿し通す挿通工程を含む
　ステータの製造方法。 [10] Includes a preparation step of preparing an annular stator core and coil segments,
The stator core has a plurality of slots arranged in parallel in the circumferential direction of the stator core, and overhanging portions extending from inner walls on both sides of the slot in the circumferential direction,
The coil segment has an insertion portion that is inserted into the slot,
The method for manufacturing a stator further includes an insertion step of inserting the insertion portion into the slot from one side in the axial direction of the stator core so that the insertion portion passes between the overhang portions on both sides in the circumferential direction.
　上記ステータの製造方法によれば、挿通部がスロット内に挿通される際、挿通部の周方向両側への変位が周方向両側の張出部によって制限される。また、挿通部がスロット内に配置された状態においても、挿通部の周方向両側への変位が周方向両側の張出部によって制限される。つまり、上記ステータの製造方法によれば、コイルを構成するコイルセグメントの挿通部が周方向に変位することを抑えることができる。 According to the stator manufacturing method described above, when the insertion portion is inserted into the slot, displacement of the insertion portion to both sides in the circumferential direction is restricted by the overhang portions on both sides in the circumferential direction. Further, even when the insertion portion is disposed in the slot, displacement of the insertion portion to both sides in the circumferential direction is limited by the overhang portions on both sides in the circumferential direction. In other words, according to the stator manufacturing method described above, displacement of the insertion portions of the coil segments that constitute the coils in the circumferential direction can be suppressed.
　〔１１〕前記張出部は、前記軸方向において前記スロット内の両側に配置され、前記内壁に支持される部位を支点として撓み変形可能であり、
　撓み変形していない状態の前記周方向両側の前記張出部間の間隔は、前記挿通部の幅よりも小さく、
　前記挿通工程では、前記スロット内の前記軸方向両側において前記周方向両側の前記張出部の間に前記挿通部が通るように、前記軸方向一方側から前記挿通部を前記スロット内に挿し通し、
　更に、前記スロット内の前記軸方向両側において前記挿通部が前記周方向両側の前記張出部の間に配置された状態において、前記軸方向両側の前記張出部の間に樹脂材料を充填する充填工程を含む
　〔１０〕に記載のステータの製造方法。 [11] The projecting portion is disposed on both sides of the slot in the axial direction, and can be flexibly deformed about a portion supported by the inner wall as a fulcrum;
The distance between the projecting portions on both sides in the circumferential direction in a state where they are not bent and deformed is smaller than the width of the insertion portion,
In the insertion step, the insertion portion is inserted into the slot from one side in the axial direction so that the insertion portion passes between the projecting portions on both sides in the circumferential direction on both sides in the axial direction within the slot. ,
Furthermore, in a state in which the insertion portion is arranged between the overhanging portions on both sides in the circumferential direction in the slot on both sides in the axial direction, a resin material is filled between the overhanging portions on both sides in the axial direction. The method for manufacturing a stator according to [10], including a filling step.
　上記ステータの製造方法によれば、軸方向両側の張出部によって樹脂材料の漏れを抑えつつ、スロット内に樹脂材料を充填させることができる。 According to the stator manufacturing method described above, it is possible to fill the slots with the resin material while suppressing leakage of the resin material by the overhangs on both sides in the axial direction.
　〔１２〕前記スロット内には、複数の前記挿通部が前記ステータコアの径方向に並んで配置され、
　前記周方向両側の前記張出部は、各々の前記挿通部と前記内壁との間に介在し、複数の前記挿通部が並ぶ方向に連続しており、
　前記充填工程では、前記軸方向両側において各々の前記挿通部が前記周方向両側の前記張出部の間に配置された状態で、前記軸方向両側の前記張出部の間に前記樹脂材料を充填する
　〔１１〕に記載のステータの製造方法。 [12] A plurality of the insertion portions are arranged in the slot in a radial direction of the stator core,
The projecting portions on both sides in the circumferential direction are interposed between each of the insertion portions and the inner wall, and are continuous in the direction in which the plurality of insertion portions are lined up;
In the filling step, the resin material is placed between the overhangs on both sides in the axial direction, with each of the insertion portions being disposed between the overhangs on both sides in the circumferential direction on both sides in the axial direction. Filling the stator manufacturing method according to [11].
　上記ステータの製造方法によれば、各々の挿通部と内壁との間の隙間を、軸方向両側の張出部によって複数の挿通部が並ぶ方向に連続的に覆いつつ、スロット内に樹脂材料を充填させることができる。 According to the stator manufacturing method described above, the gap between each insertion portion and the inner wall is continuously covered by the overhang portions on both sides in the axial direction in the direction in which the plurality of insertion portions are lined up, and the resin material is filled in the slot. Can be filled.
　＜第１実施形態＞
　１．ステータ１の構成
　第１実施形態のステータ１は、回転電機（具体的には、モータ）の部品として使用される。ステータ１は、環状、より具体的には円環状をなしている。ステータ１は、図２及び図７に示すように、ステータコア１０、コイル３０と、絶縁樹脂４０と、を備える。 <First embodiment>
1. Configuration of Stator 1 The stator 1 of the first embodiment is used as a component of a rotating electric machine (specifically, a motor). The stator 1 has an annular shape, more specifically an annular shape. The stator 1 includes a stator core 10, a coil 30, and an insulating resin 40, as shown in FIGS. 2 and 7.
　ステータコア１０は、図１に示すように、環状、より具体的には円環状をなしている。以下では、ステータコア１０の径方向を径方向と称し、ステータコア１０の軸方向を軸方向と称し、ステータコア１０の周方向を周方向と称する。なお、図１では、張出部２１、２２（図７参照）が省略されている。 As shown in FIG. 1, the stator core 10 has an annular shape, more specifically an annular shape. Hereinafter, the radial direction of stator core 10 will be referred to as the radial direction, the axial direction of stator core 10 will be referred to as the axial direction, and the circumferential direction of stator core 10 will be referred to as the circumferential direction. Note that in FIG. 1, the overhanging portions 21 and 22 (see FIG. 7) are omitted.
　ステータコア１０は、図１及び図２に示すように、ヨーク部１１と、複数のティース部１２と、を有する。ヨーク部１１は、環状、より具体的には円環状をなしている。複数のティース部１２は、ヨーク部１１の内周面に沿って環状に並んで複数設けられている。各々のティース部１２は、周方向に互いに間隔をあけて配置されている。各々のティース部１２は、ヨーク部１１の内周部から径方向内側に突出している。各々のティース部１２は、径方向及び軸方向に沿った壁状をなしている。各々のティース部１２は、径方向及び軸方向の沿った壁状をなすティース本体１３と、ティース本体１３の先端部（言い換えると、径方向内側の端部）から周方向両側に張り出したティース張出部１４と、を有する。ヨーク部１１、及び複数のティース部１２は、複数の電磁鋼板（例えばケイ素鋼板）をステータコア１０の軸方向に積層して一体に形成されている。 As shown in FIGS. 1 and 2, the stator core 10 includes a yoke portion 11 and a plurality of teeth portions 12. The yoke portion 11 has an annular shape, more specifically an annular shape. The plurality of teeth portions 12 are arranged in a ring shape along the inner circumferential surface of the yoke portion 11 . The respective teeth portions 12 are arranged at intervals from each other in the circumferential direction. Each tooth portion 12 projects radially inward from the inner peripheral portion of the yoke portion 11 . Each tooth portion 12 has a wall shape along the radial direction and the axial direction. Each tooth portion 12 includes a tooth main body 13 having a wall shape along the radial direction and the axial direction, and a tooth tension extending from the distal end portion (in other words, the inner end portion in the radial direction) of the tooth main body 13 to both sides in the circumferential direction. It has an exit part 14. The yoke portion 11 and the plurality of teeth portions 12 are integrally formed by laminating a plurality of electromagnetic steel plates (for example, silicon steel plates) in the axial direction of the stator core 10.
　ステータコア１０は、図１に示すように、複数のスロット１５を有する。複数のスロット１５は、周方向に並んで配置され、環状をなす。スロット１５は、ステータコア１０を軸方向に貫通している。スロット１５は、図２及び図７に示すように、第１開口１６と、第２開口１７と、第３開口１８と、を有する。第１開口１６は、ステータコア１０の軸方向の一方側の面に形成されている。第２開口１７は、ステータコア１０の軸方向の他方側の面に形成されている。第３開口１８は、ステータコア１０の径方向内側面に形成されている。第３開口１８は、第１開口１６及び第２開口１７に連続している。各々のスロット１５は、図２に示すように、ヨーク部１１と、隣り合う２つのティース部１２とに区画されて形成されている。 The stator core 10 has a plurality of slots 15, as shown in FIG. The plurality of slots 15 are arranged side by side in the circumferential direction and form an annular shape. Slot 15 passes through stator core 10 in the axial direction. The slot 15 has a first opening 16, a second opening 17, and a third opening 18, as shown in FIGS. 2 and 7. The first opening 16 is formed on one surface of the stator core 10 in the axial direction. The second opening 17 is formed on the other axial surface of the stator core 10 . The third opening 18 is formed on the radially inner surface of the stator core 10. The third opening 18 is continuous with the first opening 16 and the second opening 17. As shown in FIG. 2, each slot 15 is divided into a yoke portion 11 and two adjacent teeth portions 12.
　ステータコア１０は、図２及び図７に示すように、スロット１５における周方向両側の内壁から張り出した張出部２１、２２を有する。張出部２１、２２は、スロット１５の内壁に片持ち支持されており、内壁に支持される部位を支点として撓み変形し得る。張出部２１、２２は、スロット１５内の軸方向両側に設けられる。張出部２１、２２は、各々のスロット１５内に設けられる。張出部２１、２２は、ティース部１２を形成する電磁鋼板によってティース部１２と一体に形成される。この構成によれば、ステータコア１０は、部品点数の増加を抑えた形で張出部２１、２２を形成することができる。 As shown in FIGS. 2 and 7, the stator core 10 has projecting portions 21 and 22 projecting from the inner walls of the slot 15 on both sides in the circumferential direction. The projecting portions 21 and 22 are supported in a cantilever manner by the inner wall of the slot 15, and can be deformed by using the portion supported by the inner wall as a fulcrum. The projecting portions 21 and 22 are provided on both sides of the slot 15 in the axial direction. An overhang 21 , 22 is provided within each slot 15 . The overhanging portions 21 and 22 are integrally formed with the tooth portion 12 using an electromagnetic steel plate that forms the tooth portion 12. According to this configuration, the stator core 10 can form the projecting portions 21 and 22 while suppressing an increase in the number of parts.
　コイル３０は、ステータコア１０に装着される。コイル３０は、ステータコア１０（より具体的には、ティース部１２）に巻き回される。コイル３０は、分布巻であってもよいし、集中巻であってもよい。コイル３０は、分布巻である場合、波巻であってもよいし、同心巻であってもよいし、重ね巻であってもよい。本実施形態では、コイル３０を波巻として説明する。コイル３０は、スロット１５内を通ってティース部１２に巻き回されている。コイル３０は、芯線の外周を被覆で覆った被覆電線を用いて構成される。コイル３０は、本実施形態では、平角線である。なお、コイル３０は、平角線でなくてもよく、例えば、丸線であってもよい。コイル３０は、図２に示すように、コイル３０の長さ方向と直交する方向に切断した断面が矩形状をなしている。 The coil 30 is attached to the stator core 10. Coil 30 is wound around stator core 10 (more specifically, teeth portion 12). The coil 30 may have distributed winding or concentrated winding. When the coil 30 is distributed winding, it may be wave winding, concentric winding, or lap winding. In this embodiment, the coil 30 will be described as a wave-wound coil. The coil 30 passes through the slot 15 and is wound around the teeth portion 12 . The coil 30 is constructed using a covered electric wire in which the outer periphery of a core wire is covered with a coating. The coil 30 is a flat wire in this embodiment. Note that the coil 30 does not need to be a rectangular wire, and may be a round wire, for example. As shown in FIG. 2, the coil 30 has a rectangular cross section cut in a direction perpendicular to the length direction of the coil 30.
　コイル３０は、スロット１５内に挿し通される挿通部３１を有する。挿通部３１は、被覆電線を用いて構成される。挿通部３１は、スロット１５内に軸方向に挿通される。挿通部３１は、直線状をなす。挿通部３１の一端側は、スロット１５における軸方向一方側の端部（つまり、第１開口１６）から軸方向一方側に突出する。挿通部３１の他端側は、スロット１５における軸方向他方側の端部（つまり、第２開口１７）から軸方向他方側に突出する。挿通部３１は、平角線を用いて構成される。挿通部３１は、図２に示すように、挿通部３１の長さ方向（軸方向）と直交する方向に切断した断面が矩形状をなしている。コイル３０は、芯線の外周を被覆で覆った被覆電線を用いて構成される。挿通部３１は、導体部３２と、導体部３２の外周を覆う被覆部３３と、を有する。 The coil 30 has an insertion portion 31 that is inserted into the slot 15. The insertion portion 31 is constructed using a covered electric wire. The insertion portion 31 is inserted into the slot 15 in the axial direction. The insertion portion 31 has a linear shape. One end of the insertion portion 31 protrudes toward one axial side from the end of the slot 15 on one axial side (that is, the first opening 16). The other end of the insertion portion 31 protrudes from the other axial end of the slot 15 (that is, the second opening 17) toward the other axial side. The insertion portion 31 is constructed using a flat wire. As shown in FIG. 2, the insertion portion 31 has a rectangular cross section cut in a direction perpendicular to the length direction (axial direction) of the insertion portion 31. The coil 30 is constructed using a covered electric wire in which the outer periphery of a core wire is covered with a coating. The insertion portion 31 includes a conductor portion 32 and a covering portion 33 that covers the outer periphery of the conductor portion 32.
　導体部３２は、導電性を有する。導体部３２は、被覆電線の芯線を用いて構成される。導体部３２は、図７に示すように、直線状に延びる形態をなす。導体部３２は、軸方向に延びる。導体部３２は、図２に示すように、導体部３２の長さ方向と直交する方向に切断した断面が矩形状をなす。 The conductor portion 32 has electrical conductivity. The conductor portion 32 is constructed using a core wire of a covered electric wire. As shown in FIG. 7, the conductor portion 32 has a linearly extending form. The conductor portion 32 extends in the axial direction. As shown in FIG. 2, the conductor portion 32 has a rectangular cross section cut in a direction perpendicular to the length direction of the conductor portion 32.
　被覆部３３は、絶縁性を有する。被覆部３３は、被覆電線の被覆を用いて構成される。被覆部３３の材料は特に限定されない。被覆部３３は、本実施形態では、誘電率が低い低誘電率エナメルである。被覆部３３は、例えばポリビニルホルマール、熱硬化ポリウレタン、熱硬化アクリル、エポキシ、熱硬化ポリエステル、熱硬化ポリエステルイミド、芳香族ポリアミド、熱硬化ポリアミドイミド、熱硬化ポリイミド等の熱硬化性樹脂を主成分としてもよい。また、被覆部は、例えばポリエーテルイミド、ポリフェニレンエーテル、ポリエーテルサルフォン、ポリフェニレンサルファイド、ポリエーテルエーテルケトン、熱可塑性ポリイミド等の熱可塑性樹脂を主成分としてもよい。ここで「主成分」とは、最も含有量の多い成分であり、例えば５０質量％以上含有される成分である。 The covering portion 33 has insulation properties. The covering portion 33 is configured using a covering of a covered electric wire. The material of the covering portion 33 is not particularly limited. In this embodiment, the covering portion 33 is a low dielectric constant enamel having a low dielectric constant. The covering portion 33 is mainly made of a thermosetting resin such as polyvinyl formal, thermosetting polyurethane, thermosetting acrylic, epoxy, thermosetting polyester, thermosetting polyesterimide, aromatic polyamide, thermosetting polyamideimide, thermosetting polyimide, etc. Good too. Further, the covering portion may be mainly composed of a thermoplastic resin such as polyetherimide, polyphenylene ether, polyether sulfone, polyphenylene sulfide, polyether ether ketone, or thermoplastic polyimide. Here, the "main component" is the component with the highest content, for example, 50% by mass or more.
　絶縁樹脂４０は、図２に示すスロット１５Ｂのように、スロット１５内に充填されている。絶縁樹脂４０は、ステータコア１０の軸方向中央部において、スロット１５の内壁と挿通部３１との間で連続的に充填される連続充填部４１を有する。連続充填部４１は、スロット１５内の軸方向両側の張出部２１、２２の間に連続的に充填されている。この構成によれば、連続充填部４１においてスロット１５の内壁と挿通部３１との間に絶縁紙が介在しないため、挿通部３１の熱が絶縁樹脂４０を介してステータコア１０に伝達されやすく、コイル３０の熱を放出しやすい。 The insulating resin 40 is filled in the slot 15 like the slot 15B shown in FIG. The insulating resin 40 has a continuous filling portion 41 that is continuously filled between the inner wall of the slot 15 and the insertion portion 31 in the axial center of the stator core 10 . The continuous filling portion 41 is continuously filled between the projecting portions 21 and 22 on both sides in the axial direction within the slot 15 . According to this configuration, since no insulating paper is interposed between the inner wall of the slot 15 and the insertion part 31 in the continuous filling part 41, the heat of the insertion part 31 is easily transmitted to the stator core 10 via the insulating resin 40, and the coil Easily releases 30 degrees of heat.
　上述した挿通部３１は、図７に示すように、周方向両側の張出部２１、２２の間に配置される。挿通部３１は、周方向両側の張出部２１、２２の両方に接触した状態で配置される。この構成によれば、挿通部３１は、周方向両側の張出部２１、２２によって、周方向両側の変位が規制される。したがって、ステータ１は、挿通部３１の周方向両側への変位を抑えることができる。 As shown in FIG. 7, the above-mentioned insertion portion 31 is arranged between the projecting portions 21 and 22 on both sides in the circumferential direction. The insertion portion 31 is arranged in contact with both of the projecting portions 21 and 22 on both sides in the circumferential direction. According to this configuration, displacement of the insertion portion 31 on both sides in the circumferential direction is regulated by the projecting portions 21 and 22 on both sides in the circumferential direction. Therefore, the stator 1 can suppress displacement of the insertion portion 31 to both sides in the circumferential direction.
　更に、挿通部３１は、図７に示すように、軸方向両側において、周方向両側の張出部２１、２２が張出部２１、２２に接触した状態で配置される。この構成によれば、挿通部３１は、スロット１５内の軸方向両側において、自身に接触する張出部２１、２２によって、当該張出部２１、２２側への変位が規制される。したがって、ステータ１は、スロット１５内の軸方向両側において、挿通部３１が周方向に変位することを抑えることができる。 Furthermore, as shown in FIG. 7, the insertion portion 31 is arranged on both sides in the axial direction with the overhangs 21 and 22 on both sides in the circumferential direction in contact with the overhangs 21 and 22. According to this configuration, displacement of the insertion portion 31 toward the overhang portions 21 and 22 is regulated by the overhang portions 21 and 22 that come into contact with the insertion portion 31 on both sides of the slot 15 in the axial direction. Therefore, the stator 1 can suppress displacement of the insertion portion 31 in the circumferential direction on both sides of the slot 15 in the axial direction.
　図２に示すように、スロット１５内には、複数（本実施形態では４本）の挿通部３１が径方向に並んで配置される。なお、図２では、スロット１５Ａ内においては絶縁樹脂４０が省略されており、スロット１５Ｂにおいては、絶縁樹脂４０が充填された状態が示されている。周方向両側の張出部２１、２２は、各々の挿通部３１とスロット１５の周方向両側の内壁との間に介在し、複数の挿通部３１が並ぶ方向に連続している。この構成によれば、ステータ１は、スロット１５の周方向両側の内壁と各々の挿通部３１との間の隙間を、張出部２１、２２によって複数の挿通部が並ぶ方向に連続して塞ぐことができる。 As shown in FIG. 2, a plurality of (four in this embodiment) insertion portions 31 are arranged in the slot 15 in a line in the radial direction. Note that in FIG. 2, the insulating resin 40 is omitted in the slot 15A, and the slot 15B is shown filled with the insulating resin 40. The projecting portions 21 and 22 on both sides in the circumferential direction are interposed between each insertion portion 31 and the inner wall on both sides in the circumferential direction of the slot 15, and are continuous in the direction in which the plurality of insertion portions 31 are lined up. According to this configuration, the stator 1 continuously closes the gap between the inner wall on both sides of the slot 15 in the circumferential direction and each insertion portion 31 in the direction in which the plurality of insertion portions are lined up by the overhanging portions 21 and 22. be able to.
　「張出部２１、２２の径方向の長さ」は、「挿通部３１の径方向の長さ（挿通部３１の幅）」に「スロット１５内において径方向に並ぶ複数の挿通部３１の数」を乗算した値よりも大きい。張出部２１、２２の径方向内側の端部は、最も径方向内側に配置される挿通部３１よりも径方向内側に配置される。張出部２１、２２の径方向外側の端部は、最も径方向外側に配置される挿通部３１よりも径方向外側に配置される。 “The radial length of the overhanging portions 21 and 22” is the “radial length of the insertion portion 31 (width of the insertion portion 31)” and “the length of the plurality of insertion portions 31 arranged in the radial direction within the slot 15.” greater than the value multiplied by "number". The radially inner end portions of the overhanging portions 21 and 22 are arranged radially inner than the insertion portion 31 which is arranged radially innermost. The radially outer end portions of the projecting portions 21 and 22 are arranged radially outer than the insertion portion 31 which is disposed most radially outwardly.
　図７に示すように、挿通部３１に接触する周方向両側の張出部２１、２２は、いずれも挿通部３１に押圧されて撓み変形して湾曲している。張出部２１、２２の湾曲した凸面２１Ａ、２２Ａは、挿通部３１に接触した状態で配置される。張出部２１、２２の湾曲した凸面２１Ａ、２２Ａは、軸方向両側において、挿通部３１に接触した状態で配置される。この構成によれば、ステータ１は、周方向両側の張出部２１、２２からの反力によって、周方向両側の変位がより強固に規制される。したがって、ステータ１は、挿通部３１の周方向両側への変位をより確実に抑えることができる。 As shown in FIG. 7, the projecting portions 21 and 22 on both sides in the circumferential direction that contact the insertion portion 31 are both bent and deformed by being pressed by the insertion portion 31. The curved convex surfaces 21A and 22A of the projecting parts 21 and 22 are arranged in contact with the insertion part 31. The curved convex surfaces 21A and 22A of the projecting parts 21 and 22 are arranged in contact with the insertion part 31 on both sides in the axial direction. According to this configuration, the displacement of the stator 1 on both sides in the circumferential direction is more firmly regulated by the reaction forces from the projecting portions 21 and 22 on both sides in the circumferential direction. Therefore, the stator 1 can more reliably suppress displacement of the insertion portion 31 to both sides in the circumferential direction.
　図２及び図７に示すように、張出部２１、２２の凸面２１Ａ、２２Ａは、被覆部３３の表面に接触した状態で配置される。挿通部３１が被覆部３３を有する構成においては、張出部２１、２２が被覆部３３に接触することによる被覆部３３の損傷が懸念される。ステータ１は、張出部２１、２２の凸面２１Ａ、２２Ａが被覆部３３の表面に接触した状態で配置されるため、張出部２１、２２が被覆部３３に接触することによる被覆部３３の損傷を抑えることができる。 As shown in FIGS. 2 and 7, the convex surfaces 21A and 22A of the projecting parts 21 and 22 are arranged in contact with the surface of the covering part 33. In a configuration in which the insertion portion 31 has the covering portion 33, there is a concern that the covering portion 33 may be damaged due to the protruding portions 21 and 22 coming into contact with the covering portion 33. Since the stator 1 is arranged with the convex surfaces 21A and 22A of the overhanging parts 21 and 22 in contact with the surface of the covering part 33, the overhanging parts 21 and 22 contact the covering part 33, causing the covering part 33 to Damage can be suppressed.
　図７に示す例では、軸方向一方側の張出部２１、２２全体がスロット１５内に配置され、軸方向他方側の張出部２１、２２がスロット１５の外部に張り出している。しかし、軸方向両側の張出部２１、２２全体がスロット１５内に配置されてもよいし、軸方向両側の張出部２１、２２がスロット１５の外部に張り出していてもよい。 In the example shown in FIG. 7, the entire overhangs 21 and 22 on one side in the axial direction are arranged within the slot 15, and the overhangs 21 and 22 on the other side in the axial direction project outside the slot 15. However, the entire overhangs 21 and 22 on both sides in the axial direction may be disposed within the slot 15, or the overhangs 21 and 22 on both sides in the axial direction may extend outside the slot 15.
　２．ステータ１の製造方法
　ステータ１の製造方法は、準備工程と、挿通工程と、充填工程と、屈曲工程と、溶接工程と、を含む。 2. Method for manufacturing stator 1 The method for manufacturing stator 1 includes a preparation process, an insertion process, a filling process, a bending process, and a welding process.
　準備工程では、上述したステータコア１０とコイルセグメント５０とを準備する。ステータコア１０の張出部２１、２２は、図３に示すように、撓み変形していない状態において、径方向に長い矩形状をなしている。撓み変形していない状態の周方向両側の張出部２１、２２間の間隔ＧＡは、挿通部３１の幅よりも小さい。つまり、挿通部３１の幅（より具体的には、軸方向と直交し且つ複数の挿通部３１が並ぶ方向と直交する方向の挿通部３１の幅）は、スロット１５の周方向両側の内壁間の間隔ＧＢよりも小さく、撓み変形していない状態の周方向両側の張出部２１、２２間の間隔ＧＡよりも大きい。コイルセグメント５０は、例えばＵ字型をなし、２本の挿通部３１を有する。 In the preparation step, the stator core 10 and coil segments 50 described above are prepared. As shown in FIG. 3, the protruding parts 21 and 22 of the stator core 10 have a rectangular shape that is elongated in the radial direction in a state in which they are not flexibly deformed. The spacing GA between the projecting portions 21 and 22 on both sides in the circumferential direction in a state where the projecting portions 21 and 22 are not bent is smaller than the width of the insertion portion 31 . In other words, the width of the insertion portion 31 (more specifically, the width of the insertion portion 31 in the direction perpendicular to the axial direction and perpendicular to the direction in which the plurality of insertion portions 31 are arranged) is the width between the inner walls on both sides of the slot 15 in the circumferential direction. is smaller than the spacing GB, and larger than the spacing GA between the projecting portions 21 and 22 on both sides in the circumferential direction in a state where they are not flexibly deformed. The coil segment 50 is, for example, U-shaped and has two insertion portions 31 .
　挿通工程では、図４及び図５に示すように、周方向両側の張出部２１、２２の間に挿通部３１が通るように、ステータコア１０の軸方向一方側から挿通部３１をスロット１５内に挿し通す。この方法によれば、挿通部３１がスロット１５内に挿通される際、挿通部３１の周方向両側への変位が両側の張出部２１、２２によって制限される。また、挿通部３１がスロット１５内に配置された状態においても、挿通部３１の周方向両側への変位が周方向両側の張出部２１、２２によって制限される。つまり、この方法によれば、コイル３０を構成するコイルセグメント５０の挿通部３１が周方向に変位することを抑えることができる。 In the insertion step, as shown in FIGS. 4 and 5, the insertion portion 31 is inserted into the slot 15 from one side in the axial direction of the stator core 10 so that the insertion portion 31 passes between the projecting portions 21 and 22 on both sides in the circumferential direction. Insert it through. According to this method, when the insertion portion 31 is inserted into the slot 15, displacement of the insertion portion 31 to both sides in the circumferential direction is restricted by the overhang portions 21 and 22 on both sides. Further, even when the insertion portion 31 is disposed within the slot 15, displacement of the insertion portion 31 to both sides in the circumferential direction is restricted by the overhang portions 21 and 22 on both sides in the circumferential direction. That is, according to this method, displacement of the insertion portion 31 of the coil segment 50 that constitutes the coil 30 in the circumferential direction can be suppressed.
　挿通工程では、挿通部３１がスロット１５内に挿通される際、挿通部３１によって周方向両側の張出部２１、２２を撓み変形させながら張出部２１、２２の間に挿通部３１を挿し通す。この方法によれば、挿通部３１が、周方向両側の張出部２１、２２によってスロット１５の周方向中央側に寄せられる。このため、挿通部３１の被覆部３３がスロット１５の開口端に接触して損傷することを抑えることができる。 In the insertion step, when the insertion portion 31 is inserted into the slot 15, the insertion portion 31 is inserted between the overhang portions 21 and 22 while bending and deforming the overhang portions 21 and 22 on both sides in the circumferential direction. Pass. According to this method, the insertion portion 31 is moved toward the center of the slot 15 in the circumferential direction by the projecting portions 21 and 22 on both sides in the circumferential direction. Therefore, it is possible to prevent the covering portion 33 of the insertion portion 31 from coming into contact with the open end of the slot 15 and being damaged.
　挿通工程では、スロット１５内の軸方向両側において周方向両側の張出部２１、２２の間に挿通部３１が通るように、軸方向一方側から挿通部３１をスロット１５内に挿し通す。これにより、スロット１５内の軸方向両側においてスロット１５の周方向両側の内壁と挿通部３１との間の隙間を塞ぐことができる。 In the insertion step, the insertion portion 31 is inserted into the slot 15 from one side in the axial direction so that the insertion portion 31 passes between the protruding portions 21 and 22 on both sides in the circumferential direction on both sides of the slot 15 in the axial direction. Thereby, the gap between the inner wall of the slot 15 on both sides in the circumferential direction and the insertion portion 31 can be closed on both sides in the axial direction within the slot 15.
　挿通工程では、コイルセグメント５０の２本の挿通部３１が、それぞれ別々のスロット１５内に挿通される。各スロット１５には、挿通部３１が４本ずつ挿通される。 In the insertion process, the two insertion portions 31 of the coil segment 50 are inserted into separate slots 15, respectively. Four insertion portions 31 are inserted into each slot 15 .
　充填工程では、図６に示すように、スロット１５内の軸方向両側において挿通部３１が周方向両側の張出部２１、２２の間に配置された状態において、軸方向両側の張出部２１、２２の間に樹脂材料６１を充填する。この方法によれば、軸方向両側の張出部２１、２２によって樹脂材料６１の漏れを抑えつつ、スロット１５内に樹脂材料６１を充填させることができる。樹脂材料６１が硬化することで絶縁樹脂４０となる。更に、周方向両側の張出部２１、２２は、各々の挿通部３１とスロット１５の周方向両側の内壁との間に介在し、複数の挿通部３１が並ぶ方向に連続している。このため、各々の挿通部３１と周方向両側の内壁との間の隙間を、軸方向両側の張出部２１、２２によって複数の挿通部３１が並ぶ方向に連続的に覆いつつ、スロット１５内に樹脂材料６１を充填させることができる。 In the filling process, as shown in FIG. 6, in a state where the insertion portion 31 is disposed between the overhangs 21 and 22 on both sides in the circumferential direction on both sides in the axial direction in the slot 15, the overhangs 21 on both sides in the axial direction , 22 is filled with a resin material 61. According to this method, the resin material 61 can be filled into the slot 15 while suppressing leakage of the resin material 61 by the overhangs 21 and 22 on both sides in the axial direction. When the resin material 61 is cured, it becomes the insulating resin 40. Further, the projecting portions 21 and 22 on both sides in the circumferential direction are interposed between each insertion portion 31 and the inner wall on both sides in the circumferential direction of the slot 15, and are continuous in the direction in which the plurality of insertion portions 31 are lined up. For this reason, the gap between each insertion portion 31 and the inner wall on both sides in the circumferential direction is continuously covered by the overhang portions 21 and 22 on both sides in the axial direction in the direction in which the plurality of insertion portions 31 are lined up, and the inside of the slot 15 is can be filled with resin material 61.
　充填工程では、樹脂材料６１を吐出する充填装置６０が、環状のステータコア１０の内側空間に配置される。そして、充填装置６０は、樹脂材料６１の注入口６２を除き、スロット１５の径方向内側の開口（第３開口１８）を、充填装置６０のカバー６３で覆う。樹脂材料６１の注入口６２は、軸方向において、軸方向両側の張出部２１、２２の間に配置される。充填装置６０は、注入口６２から樹脂材料６１を充填することで、軸方向両側の張出部２１、２２の間に樹脂材料６１を充填する。樹脂材料６１の充填は、充填装置６０を間欠的に回転移動させることで各々のスロット１５に順に充填させる方法であってもよいし、全てのスロット１５に一度に充填させる方法であってもよい。 In the filling process, a filling device 60 that discharges the resin material 61 is placed in the inner space of the annular stator core 10. Then, the filling device 60 covers the radially inner opening (third opening 18) of the slot 15, except for the injection port 62 for the resin material 61, with a cover 63 of the filling device 60. The injection port 62 for the resin material 61 is arranged between the protrusions 21 and 22 on both sides in the axial direction. The filling device 60 fills the resin material 61 between the projecting portions 21 and 22 on both sides in the axial direction by filling the resin material 61 from the injection port 62 . The filling of the resin material 61 may be performed by intermittently rotating the filling device 60 to fill each slot 15 in turn, or by filling all the slots 15 at once. .
　屈曲工程では、コイルセグメント５０におけるスロット１５の他方側の端部から突出した部位を屈曲させる。溶接工程では、別々のスロット１５内に挿し通されたコイルセグメント５０の屈曲された部位同士を溶接する。これらの工程を経て、図７に示すように、ステータ１が完成する。 In the bending step, the portion of the coil segment 50 that protrudes from the other end of the slot 15 is bent. In the welding process, the bent portions of the coil segments 50 inserted into the separate slots 15 are welded together. Through these steps, the stator 1 is completed as shown in FIG.
　＜第２実施形態＞
　第２実施形態では、張出部が、各々の挿通部に対応して個別に設けられた個別張出部を有する例について説明する。なお、第２実施形態の説明では、第１実施形態と同じ構成について同じ符号を付し、詳しい説明を省略する。 <Second embodiment>
In the second embodiment, an example will be described in which the projecting portion includes individual projecting portions provided individually corresponding to each insertion portion. In addition, in the description of the second embodiment, the same components as in the first embodiment are denoted by the same reference numerals, and detailed description thereof will be omitted.
　図８に示すステータ２０１は、ステータコア２１０、コイル３０と、絶縁樹脂４０と、を備える。ステータコア２１０は、ヨーク部１１と、複数のティース部１２と、複数のスロット１５と、を有する。ステータコア２１０は、スロット１５における周方向両側の内壁から張り出した張出部２２１、２２２を有する。 The stator 201 shown in FIG. 8 includes a stator core 210, a coil 30, and an insulating resin 40. Stator core 210 has a yoke portion 11, a plurality of teeth portions 12, and a plurality of slots 15. Stator core 210 has projecting portions 221 and 222 projecting from inner walls on both circumferential sides of slot 15 .
　スロット１５内には、複数の挿通部３１がステータコア２１０の径方向に並んで配置される。周方向両側の張出部２２１、２２２は、各々の挿通部３１に個別に対応して設けられる個別張出部２２３、２２４を有する。周方向両側の個別張出部２２３、２２４は、それぞれ自身に対応する挿通部３１に接触した状態で配置される。この構成によれば、ステータ２０１は、各々の挿通部３１に個別に対応して設けられる個別張出部２２３、２２４によって、各々の挿通部３１が周方向両側に変位することを個別に抑えることができる。 A plurality of insertion portions 31 are arranged in the slot 15 in a line in the radial direction of the stator core 210. The projecting portions 221 and 222 on both sides in the circumferential direction have individual projecting portions 223 and 224 provided corresponding to each insertion portion 31 individually. The individual projecting portions 223 and 224 on both sides in the circumferential direction are arranged in contact with the corresponding insertion portions 31, respectively. According to this configuration, the stator 201 can individually suppress displacement of each insertion portion 31 to both sides in the circumferential direction by the individual projecting portions 223 and 224 provided correspondingly to each insertion portion 31. Can be done.
　ステータ２０１の製造方法は、第１実施形態のステータ１の製造方法と同じであるが、構成の違いに起因して以下の違いが生じる。 The method of manufacturing the stator 201 is the same as the method of manufacturing the stator 1 of the first embodiment, but the following differences occur due to the difference in configuration.
　各々の個別張出部２２３、２２４は、自身に対応する挿通部３１とスロット１５内の周方向両側の内壁との間に配置され、当該内壁に支持される部位を支点として互いに独立して撓み変形可能である。個別張出部２２３、２２４は、図９に示すように、撓み変形していない状態において、径方向に長い矩形状をなしている。個別張出部２２３、２２４が撓み変形していない状態において、周方向両側の個別張出部２２３、２２４間の間隔ＧＣは、挿通部３１の幅よりも小さい。つまり、挿通部３１の幅（より具体的には、軸方向と直交し且つ複数の挿通部３１が並ぶ方向と直交する方向の挿通部３１の幅）は、スロット１５の周方向両側の内壁間の間隔ＧＢよりも小さく、撓み変形していない状態の周方向両側の個別張出部２２３、２２４間の間隔ＧＣよりも大きい。 Each of the individual protruding parts 223 and 224 is arranged between the corresponding insertion part 31 and the inner walls on both sides in the circumferential direction within the slot 15, and is bent independently of each other using the parts supported by the inner walls as fulcrums. Deformable. As shown in FIG. 9, the individual projecting portions 223 and 224 have a radially long rectangular shape in a state in which they are not bent or deformed. In a state where the individual projecting portions 223 and 224 are not flexibly deformed, the distance GC between the individual projecting portions 223 and 224 on both sides in the circumferential direction is smaller than the width of the insertion portion 31. In other words, the width of the insertion portion 31 (more specifically, the width of the insertion portion 31 in the direction perpendicular to the axial direction and perpendicular to the direction in which the plurality of insertion portions 31 are arranged) is the width between the inner walls on both sides of the slot 15 in the circumferential direction. is smaller than the spacing GB, and larger than the spacing GC between the individual projecting portions 223 and 224 on both sides in the circumferential direction in a state where they are not flexibly deformed.
　挿通工程では、挿通部３１がスロット１５内に挿通される際、挿通部３１によって当該挿通部３１に対応する個別張出部２２３、２２４を撓み変形させながら個別張出部２２３、２２４の間に挿通部３１を挿し通す。この方法によれば、各々の個別張出部２２３、２２４が、自身に対応する挿通部３１の位置に合わせて個別に変位するため、周方向において張出部２２１、２２２と挿通部３１との間に隙間が生じにくくなる。 In the insertion step, when the insertion portion 31 is inserted into the slot 15, the insertion portion 31 bends and deforms the individual protrusion portions 223 and 224 corresponding to the insertion portion 31, and the insertion portion 31 is inserted between the individual protrusion portions 223 and 224. Insert the insertion portion 31 through. According to this method, each of the individual projecting portions 223 and 224 is individually displaced according to the position of the corresponding insertion portion 31, so that the respective projecting portions 221 and 222 and the insertion portion 31 are displaced in the circumferential direction. There will be fewer gaps between them.
　＜他の実施形態＞
　本開示は、上記記述及び図面によって説明した実施形態に限定されるものではない。例えば、上述又は後述の実施形態の特徴は、矛盾しない範囲であらゆる組み合わせが可能である。また、上述又は後述の実施形態のいずれの特徴も、必須のものとして明示されていなければ省略することもできる。更に、上述した実施形態は、次のように変更されてもよい。 <Other embodiments>
The present disclosure is not limited to the embodiments described above and illustrated in the drawings. For example, the features of the embodiments described above or below can be combined in any combination without contradicting each other. Furthermore, any feature of the embodiments described above or below may be omitted unless explicitly stated as essential. Furthermore, the embodiment described above may be modified as follows.
　上記各実施形態では、張出部がティース部と同一部材で一体に形成される構成であったが、張出部がティース部と別部材で形成される構成であってもよい。 In each of the above embodiments, the overhang portion and the teeth portion are integrally formed of the same member, but the overhang portion may be formed of a separate member from the teeth portion.
　上記各実施形態では、挿通部が周方向両側の張出部の両方に接触する構成であったが、片方にのみ接触する構成であってもよい。 In each of the above embodiments, the insertion portion was configured to contact both of the protruding portions on both sides in the circumferential direction, but may be configured to contact only one side.
　上記各実施形態では、周方向両側の張出部がいずれも撓み変形して湾曲した構成であったが、周方向両側の張出部のうち片方のみが撓み変形して湾曲した構成であってもよいし、いずれも湾曲していない構成であってもよい。 In each of the above embodiments, the overhanging portions on both sides in the circumferential direction are both bent and curved, but only one of the overhanging portions on both sides in the circumferential direction is bent and bent. Alternatively, neither of them may be curved.
　上記各実施形態では、張出部の凸面が挿通部に接触する構成であったが、張出部の張出端部が挿通部に接触する構成であってもよい。 In each of the above embodiments, the convex surface of the overhanging portion is in contact with the insertion portion, but the overhanging end of the overhanging portion may be in contact with the insertion portion.
　なお、今回開示された実施の形態は全ての点で例示であって制限的なものではないと考えられるべきである。本発明の範囲は、今回開示された実施の形態に限定されるものではなく、請求の範囲によって示された範囲内又は請求の範囲と均等の範囲内での全ての変更が含まれることが意図される。 It should be noted that the embodiments disclosed herein are illustrative in all respects and should not be considered restrictive. The scope of the present invention is not limited to the embodiments disclosed herein, and is intended to include all modifications within the scope indicated by the claims or within the range equivalent to the claims. be done.
１…ステータ
１０…ステータコア
１１…ヨーク部
１２…ティース部
１３…ティース本体
１４…ティース張出部
１５…スロット
１５Ａ…スロット
１５Ｂ…スロット
１６…第１開口
１７…第２開口
１８…第３開口
２１…張出部
２１Ａ…凸面
２２…張出部
２２Ａ…凸面
３０…コイル
３１…挿通部
３２…導体部
３３…被覆部
４０…絶縁樹脂
４１…連続充填部
４４…被覆部
５０…コイルセグメント
６０…充填装置
６１…樹脂材料
６２…注入口
６３…カバー
２０１…ステータ
２１０…ステータコア
２２１…張出部
２２２…張出部
２２３…個別張出部
２２４…個別張出部 1... Stator 10... Stator core 11... Yoke part 12... Teeth part 13... Teeth body 14... Teeth overhanging part 15... Slot 15A... Slot 15B... Slot 16... First opening 17... Second opening 18... Third opening 21... Overhanging portion 21A...Convex surface 22...Overhanging section 22A...Convex surface 30...Coil 31...Insertion section 32...Conductor section 33...Coating section 40...Insulating resin 41...Continuous filling section 44...Coating section 50...Coil segment 60...Filling device 61...Resin material 62...Inlet 63...Cover 201...Stator 210...Stator core 221...Overhang section 222...Overhang section 223...Individual overhang section 224...Individual overhang section

Claims (12)

  1. 　環状のステータコアと、
    　前記ステータコアに装着されるコイルと、を備え、
    　前記ステータコアは、前記ステータコアの周方向に並んで配置される複数のスロットと、前記スロットにおける前記周方向両側の内壁から張り出した張出部と、を有し、
    　前記コイルは、前記スロット内に挿し通される挿通部を有し、
    　前記挿通部は、前記周方向両側の前記張出部の間において、少なくとも一方の前記張出部に接触した状態で配置される
    　ステータ。     an annular stator core;
    A coil attached to the stator core,
    The stator core has a plurality of slots arranged in parallel in the circumferential direction of the stator core, and overhanging portions extending from inner walls on both sides of the slot in the circumferential direction,
    The coil has an insertion part that is inserted into the slot,
    The said insertion part is arrange|positioned between the said overhang parts on both sides of the said circumferential direction in the state which contacted at least one said overhang part. Stator.
  2. 　前記挿通部は、前記周方向両側の前記張出部に接触した状態で配置される
    　請求項１に記載のステータ。     The stator according to claim 1, wherein the insertion portion is arranged in contact with the projecting portions on both sides in the circumferential direction.
  3. 　前記スロット内には、複数の前記挿通部が前記ステータコアの径方向に並んで配置され、
    　前記周方向両側の前記張出部は、各々の前記挿通部と前記周方向両側の前記内壁との間に介在し、複数の前記挿通部が並ぶ方向に連続している
    　請求項１又は請求項２に記載のステータ。     A plurality of the insertion portions are arranged in the slot in a radial direction of the stator core,
    The projecting portions on both sides in the circumferential direction are interposed between each of the insertion portions and the inner walls on both sides in the circumferential direction, and are continuous in the direction in which the plurality of insertion portions are lined up. 2. The stator according to 2.
  4. 　前記スロット内には、複数の前記挿通部が前記ステータコアの径方向に並んで配置され、
    　前記周方向両側の前記張出部は、各々の前記挿通部に個別に対応して設けられる個別張出部を有し、
    　各々の前記個別張出部は、前記周方向両側の前記個別張出部のうち少なくとも片方の前記個別張出部が自身に対応する前記挿通部に接触した状態で配置される
    　請求項１又は請求項２に記載のステータ。     A plurality of the insertion portions are arranged in the slot in a radial direction of the stator core,
    The projecting portions on both sides in the circumferential direction have individual projecting portions provided corresponding to each of the insertion portions,
    Each of the individual projecting portions is arranged such that at least one of the individual projecting portions on both sides in the circumferential direction is in contact with the corresponding insertion portion. The stator according to item 2.
  5. 　前記挿通部に接触する前記周方向両側の前記張出部のうち少なくとも片方の前記張出部は、前記挿通部に押圧されて撓み変形して湾曲しており、湾曲した凸面が前記挿通部に接触した状態で配置される
    　請求項２に記載のステータ。     At least one of the projecting parts on both sides in the circumferential direction that contacts the insertion part is bent and deformed by being pressed by the insertion part, and the curved convex surface is attached to the insertion part. The stator according to claim 2, wherein the stator is arranged in contact.
  6. 　前記挿通部は、導体部と、前記導体部の外周を覆う被覆部と、を有し、
    　前記凸面は、前記被覆部の表面に接触した状態で配置される
    　請求項５に記載のステータ。     The insertion part has a conductor part and a covering part that covers the outer periphery of the conductor part,
    The stator according to claim 5, wherein the convex surface is arranged in contact with a surface of the covering section.
  7. 　前記ステータコアは、環状のヨーク部と、前記ヨーク部に沿って環状に並ぶ複数のティース部と、を有し、
    　各々の前記スロットは、前記ヨーク部と隣り合う２つの前記ティース部とに区画されて形成され、
    　前記ヨーク部、及び複数の前記ティース部は、複数の電磁鋼板を前記ステータコアの軸方向に積層して一体に形成され、
    　前記張出部は、前記電磁鋼板によって前記ティース部と一体に形成されている
    　請求項１又は請求項２に記載のステータ。     The stator core has an annular yoke portion and a plurality of teeth portions arranged annularly along the yoke portion,
    Each of the slots is divided into the yoke portion and the two adjacent teeth portions,
    The yoke portion and the plurality of teeth portions are integrally formed by laminating a plurality of electromagnetic steel plates in the axial direction of the stator core,
    The stator according to claim 1 or 2, wherein the projecting portion is integrally formed with the teeth portion from the electromagnetic steel plate.
  8. 　前記張出部は、前記ステータコアの軸方向において前記スロット内の両側に設けられ、
    　前記挿通部は、前記スロット内の前記軸方向両側において、前記周方向両側の前記張出部のうち少なくとも一方の前記張出部に接触した状態で配置される
    　請求項１又は請求項２に記載のステータ。     The projecting portion is provided on both sides within the slot in the axial direction of the stator core,
    The insertion portion is arranged on both sides of the slot in the axial direction so as to be in contact with at least one of the overhang portions on both sides in the circumferential direction. stator.
  9. 　更に、前記スロット内に充填される絶縁樹脂を備え、
    　前記絶縁樹脂は、前記軸方向両側の前記張出部の間において、前記周方向両側の前記内壁と前記挿通部との間で連続的に充填される連続充填部を有する
    　請求項８に記載のステータ。     Further, an insulating resin filled in the slot,
    The insulating resin has a continuous filling part that is continuously filled between the inner wall on both sides in the circumferential direction and the insertion part between the overhang parts on both sides in the axial direction. stator.
  10. 　環状のステータコアとコイルセグメントとを準備する準備工程を含み、
    　前記ステータコアは、前記ステータコアの周方向に並んで配置される複数のスロットと、前記スロットにおける前記周方向両側の内壁から張り出した張出部と、を有し、
    　前記コイルセグメントは、前記スロット内に挿し通される挿通部を有し、
    　更に、前記周方向両側の前記張出部の間に前記挿通部が通るように、前記ステータコアの軸方向一方側から前記挿通部を前記スロット内に挿し通す挿通工程を含む
    　ステータの製造方法。     a preparation step of preparing an annular stator core and a coil segment;
    The stator core has a plurality of slots arranged in parallel in the circumferential direction of the stator core, and overhanging portions extending from inner walls on both sides of the slot in the circumferential direction,
    The coil segment has an insertion portion that is inserted into the slot,
    The method for manufacturing a stator further includes an insertion step of inserting the insertion portion into the slot from one side in the axial direction of the stator core so that the insertion portion passes between the overhang portions on both sides in the circumferential direction.
  11. 　前記張出部は、前記軸方向において前記スロット内の両側に配置され、前記内壁に支持される部位を支点として撓み変形可能であり、
    　撓み変形していない状態の前記周方向両側の前記張出部間の間隔は、前記挿通部の幅よりも小さく、
    　前記挿通工程では、前記スロット内の前記軸方向両側において前記周方向両側の前記張出部の間に前記挿通部が通るように、前記軸方向一方側から前記挿通部を前記スロット内に挿し通し、
    　更に、前記スロット内の前記軸方向両側において前記挿通部が前記周方向両側の前記張出部の間に配置された状態において、前記軸方向両側の前記張出部の間に樹脂材料を充填する充填工程を含む
    　請求項１０に記載のステータの製造方法。     The projecting portion is disposed on both sides of the slot in the axial direction, and can be flexibly deformed about a portion supported by the inner wall as a fulcrum,
    The distance between the projecting portions on both sides in the circumferential direction in a state where they are not bent and deformed is smaller than the width of the insertion portion,
    In the insertion step, the insertion portion is inserted into the slot from one side in the axial direction so that the insertion portion passes between the projecting portions on both sides in the circumferential direction on both sides in the axial direction within the slot. ,
    Furthermore, in a state in which the insertion portion is arranged between the overhanging portions on both sides in the circumferential direction in the slot on both sides in the axial direction, a resin material is filled between the overhanging portions on both sides in the axial direction. The method for manufacturing a stator according to claim 10, comprising a filling step.
  12. 　前記スロット内には、複数の前記挿通部が前記ステータコアの径方向に並んで配置され、
    　前記周方向両側の前記張出部は、各々の前記挿通部と前記内壁との間に介在し、複数の前記挿通部が並ぶ方向に連続しており、
    　前記充填工程では、前記軸方向両側において各々の前記挿通部が前記周方向両側の前記張出部の間に配置された状態で、前記軸方向両側の前記張出部の間に前記樹脂材料を充填する
    　請求項１１に記載のステータの製造方法。     A plurality of the insertion portions are arranged in the slot in a radial direction of the stator core,
    The projecting portions on both sides in the circumferential direction are interposed between each of the insertion portions and the inner wall, and are continuous in the direction in which the plurality of insertion portions are lined up;
    In the filling step, the resin material is inserted between the overhangs on both sides in the axial direction, with each of the insertion portions being disposed between the overhangs on both sides in the circumferential direction on both sides in the axial direction. The method for manufacturing a stator according to claim 11, wherein the stator is filled.
PCT/JP2023/029686 2022-09-01 2023-08-17 Stator and method for manufacturing stator WO2024048294A1 (en)

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2007037202A (en) * 2003-10-31 2007-02-08 Neomax Co Ltd Rotor for permanent magnet embedded motor, its assembling method, and assembling device
JP2007312549A (en) * 2006-05-19 2007-11-29 Denso Corp Stator of rotary electric machine and manufacturing method therefor
JP2015033192A (en) * 2013-08-01 2015-02-16 トヨタ自動車株式会社 Method for manufacturing rotary electric machine stator and rotary electric machine stator
JP2015136245A (en) * 2014-01-17 2015-07-27 トヨタ自動車株式会社 Rotor of motor
JP2018137836A (en) * 2017-02-20 2018-08-30 本田技研工業株式会社 Stator and rotary electric machine
JP2018164374A (en) * 2017-03-27 2018-10-18 本田技研工業株式会社 Core unit for rotary electric machine and rotary electric machine

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2007037202A (en) * 2003-10-31 2007-02-08 Neomax Co Ltd Rotor for permanent magnet embedded motor, its assembling method, and assembling device
JP2007312549A (en) * 2006-05-19 2007-11-29 Denso Corp Stator of rotary electric machine and manufacturing method therefor
JP2015033192A (en) * 2013-08-01 2015-02-16 トヨタ自動車株式会社 Method for manufacturing rotary electric machine stator and rotary electric machine stator
JP2015136245A (en) * 2014-01-17 2015-07-27 トヨタ自動車株式会社 Rotor of motor
JP2018137836A (en) * 2017-02-20 2018-08-30 本田技研工業株式会社 Stator and rotary electric machine
JP2018164374A (en) * 2017-03-27 2018-10-18 本田技研工業株式会社 Core unit for rotary electric machine and rotary electric machine

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