WO2024101340A1

WO2024101340A1 - Insulation member, coil unit, stator, motor, and stator manufacturing method

Info

Publication number: WO2024101340A1
Application number: PCT/JP2023/039994
Authority: WO
Inventors: 武延本郷; 由智赤羽根
Original assignee: 株式会社アスター
Priority date: 2022-11-10
Filing date: 2023-11-07
Publication date: 2024-05-16
Also published as: JP2024069818A

Abstract

Provided is an insulation member with which it is possible to prevent the narrowing of the magnetic path of a core, increase the performance of a motor, improve the productivity of a stator and, by extension, the productivity of the motor, and reduce the number of components. A coil unit, a stator, a motor, and a stator manufacturing method are also provided.　The insulation member 30 includes: an insulation main body 31 that can insulate a core 51 from a coil 10 attachable to the core 51, and that is disposed between the coil 10 and the core 51; a first engaging part 35 that can engage with the coil 10; and a second engaging part 36 that can engage with the core 51 by extending or protruding in the radial direction of a stator 50 from the insulation main body 31.

Description

Insulating member, coil unit, stator, motor, and method of manufacturing stator

The present invention relates to an insulating member disposed between a concentrated winding coil and a motor core, a coil unit, a stator, a motor, and a method for manufacturing a stator.

Conventionally, a stator, which is a component of a motor, has a core that is made up of an annular yoke and multiple teeth, and a coil is attached to the core. The coil is wound around the teeth and accommodated in a slot created between adjacent teeth. In this type of configuration, a wedge plate is provided as a means for preventing the coil from jumping out of the slot (see, for example, Patent Document 1).

FIG. 17 is a plan view showing a portion of a conventional stator 200 as seen from the axis M0 of the motor. In the example of FIG. 17, a core 201 has an annular yoke portion 202 and multiple teeth 203 that protrude radially inward (in the axial direction of the motor) from the yoke portion 202. Each of the multiple teeth 203 has a concentrated winding coil 205 attached via an insulating sheet 204. This defines a slot 206 between adjacent teeth 203, and the slot 206 houses parts of two adjacent coils 205.

Furthermore, a wedge plate 208 is attached to the opening 207 side of the slot 206. The wedge plate 208 is a flat plate member, for example, approximately U-shaped or approximately rectangular O-shaped, that conforms to the outer circumferential shape of the teeth portion 203, and is attached to each teeth portion 203 so that the opposing arm portions sandwich the side surface of each teeth portion 203 in the circumferential direction C.

More specifically, the wedge plate 208 has engaging protrusions 208c on both ends in the circumferential direction C. Also, an engaging recess 203r is provided on the side surface of each tooth portion 203 in the circumferential direction C. The wedge plate 208 is fixed to the tooth portion 203 by fitting the engaging protrusions 208c into the engaging recesses 203c. This prevents the coil 205 from coming off the tooth portion 203 (or moving in the radial direction of the motor).

JP 2016-158403 A

However, when the motor is in operation, the teeth 203 generate magnetic flux as shown by the dashed line in FIG. 17, and if the teeth 203 are provided with the engagement recesses 203c, the magnetic path becomes narrower in that area. This reduces the amount of magnetic flux, which creates a problem of not being able to improve the motor characteristics.

Furthermore, for each tooth portion 203, a process for attaching the insulating sheet 204, a process for attaching the coil 205, and a process for attaching the wedge plate 208 are required. In this case, the number of assembly steps is large, and the insulating sheet 204, which has low rigidity, is difficult to handle, resulting in poor production efficiency and a large number of parts.

The present invention aims to provide an insulating member, coil unit, stator, motor, and stator manufacturing method that can prevent the magnetic path of the core from narrowing, improve motor performance, and increase the productivity of the stator and therefore the motor, while reducing the number of parts.

The present invention relates to an insulating member capable of insulating a stator core from a coil that can be attached to the core, characterized in that the insulating member has an insulating body portion disposed between the coil and the core, a first engagement portion that can engage with the coil, and a second engagement portion that extends or protrudes from the insulating body portion in the radial direction of the stator and can engage with the core.

The present invention also relates to an insulating member capable of insulating a stator core from a coil that can be attached to the core, characterized in that the insulating member has an insulating main body portion disposed between the coil and the core, a first engaging portion that can engage with the coil, and a second engaging portion that can engage with a surface that constitutes the outer or inner circumference of a substantially annular yoke portion of the core.

The present invention also relates to a coil unit characterized in that the insulating member, the core member constituting the core, and the coil are integrally engaged.

The present invention also relates to a stator in which the insulating member is interposed between the coil and the core.

The present invention also relates to a motor having the above-mentioned stator.

The present invention also relates to a method for manufacturing a stator using the above insulating member, characterized in that after engaging the coil with the first engaging portion, the core with the second engaging portion is engaged.

The present invention can provide an insulating member, coil unit, stator, motor, and stator manufacturing method that can prevent the magnetic path of the core from narrowing, improve motor performance, and increase the productivity of the stator and therefore the motor, while reducing the number of parts.

1 is a cross-sectional view showing a motor according to a first embodiment of the present invention. 1A and 1B are diagrams showing a stator according to a first embodiment, in which FIG. 1A is a plan view of a core according to a first embodiment, FIG. 1B is a plan view of the core, and FIG. 1C is a perspective view of the core's appearance. 1A, 1B, and 1C are diagrams showing a coil according to a first embodiment, in which (A) is a front view, (B) is a side view, and (C) is a bottom view. 1A to 1E are diagrams showing a coil unit according to a first embodiment, in which (A) is a cross-sectional view, (B) a plan view, (C) a front view, (D) a rear view, and (E) a side view. 1A to 1E are diagrams showing an insulating member according to a first embodiment, in which (A) is an external perspective view, (B) a front view, (C) a rear view, (D) a side view, and (E) a plan view. 4 is a flowchart illustrating a method for manufacturing the coil unit according to the first embodiment. 1A to 1E are diagrams illustrating a manufacturing method of a coil unit according to a first embodiment, in which (A) is a side view, and (B) to (E) are schematic plan views. 5A to 5C are side views illustrating a manufacturing method of the coil unit according to the first embodiment. 4 is a perspective view illustrating a manufacturing method of the stator according to the first embodiment. FIG. 5A to 5C are diagrams showing a second embodiment of the present invention, in which (A) is a plan view of a core, (B) is a side view of an insulating member, and (C) is a plan view of the insulating member. 11A to 11F are diagrams showing a manufacturing method of a coil unit according to a second embodiment, in which (A) is a plan view, (B) is a plan view, (C) is a side view, (D) is a plan view, (E) is a plan view, and (F) is a side view. 10A to 10D are diagrams illustrating a method for manufacturing a stator according to a second embodiment, in which (A) is a plan view, (B) is a plan view, (C) is a side view, and (D) is a plan view. 13A to 13C are diagrams showing a third embodiment of the present invention, in which (A) is a plan view of a core, (B) is a side view of an insulating member, and (C) is a plan view of the insulating member. 13A to 13C are diagrams showing a method for manufacturing a coil unit according to a third embodiment, in which (A) is a plan view, (B) is a plan view, and (C) is a side view. 13A to 13D are diagrams illustrating a method for manufacturing a stator according to a third embodiment, in which (A) is a plan view, (B) a side view, (C) a plan view, (C) a side view, and (D) a plan view. FIG. 1 is a plan view showing a conventional motor.

Below, an embodiment of the present invention will be described in detail with reference to the drawings. Note that in this and subsequent figures, some components will be omitted as appropriate to simplify the drawings. Also, in this and subsequent figures, the size, shape, thickness, etc. of components will be exaggerated as appropriate.

First Embodiment
<Motor>
First, a motor 100 according to the present invention will be described with reference to Fig. 1. Fig. 1 is a cross-sectional view for explaining an overview of the motor 100 according to the present embodiment. Fig. 1 shows an inner rotor type motor 100 as an example.

Directions in this embodiment are defined based on the motor 100. The axial center of the motor 100 is hereinafter referred to as the motor axis M0. Specifically, the direction of rotation centered on the motor axis M0 is referred to as the circumferential direction C (of the motor 100), the extension direction of a line segment passing through the motor axis M0 in a plan view seen from the direction of the motor axis M0 (the vertical direction in FIG. 1) is referred to as the radial direction R (of the motor 100), the side of the radial direction R closer to the motor axis M0 is referred to as the radial inner side RI, and the side farther from the motor axis M0 is referred to as the radial outer side RO.

As shown in FIG. 1, the motor 100 is, for example, a three-phase motor, and has a case (housing) 90, a shaft 80, a rotor 70, a stator 50, etc., and is assembled so that the rotor 70 can rotate relative to the stator 50. The shaft 80 is a columnar member, and rotates (in the circumferential direction C) around its central axis (motor axis M0) while being supported by, for example, a bearing 82. A device to be driven (not shown) is connected to one end of the shaft 80 via a power transmission mechanism such as a gear.

The rotor 70 has magnets 71 arranged in the circumferential direction C, and rotates together with the shaft 80. In this example, the stator 50 is arranged on the outside of the rotor 70 in the radial direction R. The stator 50 has coils 10 attached to it so that they are aligned in the circumferential direction C, and the coils 10 generate a force for rotating the rotor 70. Although detailed illustration will be omitted below, the external terminals of the stator 50 are connected to a drive circuit or power source that supplies power to the motor 100, for example, via lead wires. As shown in the figure, the case (housing) 90 has a roughly cylindrical shape that covers the stator 50 and the rotor 70 as a whole. The case 90 is fixed to the shaft 80.

The motor 100 applies a driving current to the coil 10 from a power source or a driving circuit via a bus bar (not shown). This generates a magnetic flux in the stator 50 (the teeth 54). Then, the action of the magnetic flux between the teeth 54 and the magnet 71 generates a torque in the circumferential direction C. As a result, the rotor 70 and the case 90 rotate around the axis of the shaft 80 (motor axis M0) relative to the stator 50.

FIG. 2 shows the stator 50 in isolation, with FIG. 2(A) being a plan view as seen from the direction of the motor shaft M0, and FIG. 2(B) being a perspective view. FIG. 3 shows the core 51, with FIG. 3(A) being a plan view of the core 51 as seen from the direction of the motor shaft M0, FIG. 3(B) being a plan view showing a portion of the core 51 (core member 52), and FIG. 3(C) being an external perspective view showing a portion of the core 51 (core member 52).

2 and 3, the stator 50 has a substantially annular core 51 and a plurality of coils 10 attached to the core 51. In detail, the core 51 of the stator 50 has a substantially annular yoke portion 53 and a plurality of teeth portions 54 protruding from the yoke portion 53 in the direction of the motor shaft M0 (radially inward RI).

3A, the core 51 of this embodiment is composed of a core member 52 (split core) divided into multiple parts in the circumferential direction C so that the multiple teeth 54 are independent of each other. As shown in FIGS. 3B and 3C, the core member 52 has one tooth 54 and a split yoke portion 53P, and is a member configured in a substantially T-shape in a plan view. The split yoke portion 53P is continuous with the base end side when the motor shaft M0 side (radial inner side RI) of the teeth portion 54 is the tip in the protruding direction. The radial outer side RO surface (outer side surface 532) of the split yoke portion 53P is a surface that constitutes the outer peripheral surface 53O of the substantially annular yoke portion 53, and a recess 533 extending in the motor shaft M0 direction is provided in a part of it (see FIG. 2B). An alignment means (such as a jig not shown) can be inserted or engaged into the recess 533 when arranging the multiple core members 52 in the circumferential direction C. Then, one split yoke portion 53P is connected to another split yoke portion 53P in the circumferential direction C to form a substantially annular yoke portion 53 (Figure 3(A)).

FIG. 4 is a diagram showing an example of the coil 10 of this embodiment. FIG. 4(A) is a front view seen from the direction of the motor axis M0 when attached to the stator 50, FIG. 4(B) is a side view seen from the right direction of FIG. 4(A), and FIG. 4(C) is a plan (bottom) view seen from below of FIG. 4(A).

The coil 10 of this embodiment is attached to the stator 50 as an example. The coil 10 is a spiral structure, and is a so-called concentrated winding coil in which multiple regions (indicated by the large dashed arrow in FIG. 1A, hereafter referred to as "one-circumference regions CR") that revolve around the spiral axis SC are wound so as to be substantially overlapping in the direction of the spiral axis SC.

The coil 10 in this example is an edgewise coil. An edgewise coil may be one in which a plurality of strip-shaped flat conductors (coil pieces) are connected in series to form a spiral structure (in the completed state, the flat conductors are configured as wound), or one in which a long flat conductor is wound to form a spiral structure. In these cases, the flat conductor may be one that is pressed from a round (conductor) wire. It may also be one in which a round (conductor) wire is wound to form a spiral structure.

The coil 10 shown in Figure 4 has insulating resin applied around the conductor (e.g., flat conductor) that constitutes the spiral structure (detailed illustration is omitted). The insulating resin is provided continuously along the direction of the spiral from one end ST to the other end ET of the coil 10, and one circumference region CR of the spiral structure is insulated by the insulating resin. Note that the ends of the coil 10 (one end ST and the other end ET) are connection parts (terminals) with other members, and insulating resin does not necessarily have to be provided thereon.

FIG. 5 is a diagram showing the coil unit 20 of this embodiment. FIG. 5(A) is a diagram showing the coil unit 20 constituting the stator 50, a schematic diagram showing a part of the stator 50 as seen from the motor axis M0 direction, and a cross-sectional view taken along a plane perpendicular to the motor axis M0. FIG. 5(B) is a plan view of one coil unit 20 as seen from the motor axis M0 direction, FIG. 5(C) is a front view of the coil unit 20 as seen from the radial inside RI, FIG. 5(D) is a rear view of the coil unit 20 as seen from the radial outside RO, and FIG. 5(E) is a side view of the coil unit 20 as seen from the circumferential direction C (the left side of FIG. 5(C)).

The coil unit 20 of this embodiment is an integrated unit of the core member 52 shown in Figures 3(B) and 3(C), the coil 10 shown in Figure 4, and the insulating member 30.

Each coil 10 is attached to one core member 52. More specifically, in this embodiment, the coil 10 is attached to the outside of one tooth portion 54. Each coil 10 is a spiral structure in which a region CR of a conductor that goes around the outside of one tooth portion 54 is repeatedly overlapped in the protruding direction of the tooth portion 54.

As shown in Figures 5(A) and 5(B), when each coil 10 is attached to the teeth portion 54, the radially innermost one-circumference region CR (innermost one-circumference region CRI) faces the rotor 70, and the radially outermost one-circumference region CR (outermost one-circumference region CRO) faces the inner surface 531 of the split yoke portion 53P that is continuous with the base end side of the teeth portion 54, via the insulating member 30.

The outer surface 532 of the split yoke portion 53P is a curved surface (part of the outer surface 53O) that constitutes the outer periphery of the substantially annular yoke portion 53, but the inner surface 531 of the split yoke portion 53P is a flat surface that conforms to the surface of the region CR of the coil 10 for one revolution.

An insulating member 30 is interposed between the coil 10 and the core member 52. In detail, the insulating member 30 is a resin molded body, and is configured to cover the inner surface 531 of the split yoke portion 53P and the circumferential side surface 541 of the teeth portion 54 (the surface facing the inner peripheral surface of the spiral structure of the coil 10). The insulating member 30 insulates the coil 10 and the core member 52 and fixes them together to form the coil unit 20.

The insulating member 30 has a first engaging portion 35 and a second engaging portion. The first engaging portion 35 engages with the inner circumference of the spiral structure of the coil 10. The second engaging portion 36 engages with the recess 533 of the core member 52. This prevents the coil 10 from coming off the teeth portion 54. Therefore, a wedge plate that blocks the opening OP of the slot defined by adjacent teeth portions 54 is not required.

FIG. 6 shows the insulating member 30, where FIG. 6(A) is an external perspective view seen from the circumferential direction C, FIG. 6(B) is a front view seen from the radially inner side RI, FIG. 6(C) is a rear view seen from the radially outer side RO, FIG. 6(D) is a side view seen from the circumferential direction C (the left side of FIG. 6(B)), and FIG. 6(E) is a plan view seen from the direction of the motor shaft M0.

The insulating member 30 has an insulating main body 31, a first engaging portion 35, and a second engaging portion 36, and is a resin molded body in which these are integrally molded from an insulating resin material, and is capable of insulating the core 51 (core member 52) from the coil 10.

The insulating body portion 31 is disposed between the coil 10 and the core 51. In detail, the insulating body portion 31 has a sleeve portion 32 and a flange portion 33, as shown in FIG. 6(A). The sleeve portion 32 is a generally rectangular tube with openings at both ends in the radial direction R (the tip and base ends of the teeth portion 54), and the teeth portion 54 can be inserted into it. In other words, the sleeve portion 32 is a generally rectangular tube that conforms to the shape of the teeth portion 54, and can be disposed close to or in close contact with the outside of the teeth portion 54 (with the outer surface) (see FIG. 5).

The flange portion 33 is provided around the opening on one side of the sleeve portion 32 (the radially outer side RO, the base end side of the teeth portion 54) and has a roughly rectangular shape that corresponds to the shape of the inner surface 531 of the split yoke portion 53P of the core member 52 (Figures 6(B) and 6(C)), and can be positioned facing the inner surface 531 in close proximity or in close contact with it (see Figure 5).

Hereinafter, the sleeve portion 32 corresponds to the teeth portion 54, and the radially inner side RI of the sleeve portion 32 is referred to as the tip side, and the radially outer side RO of the sleeve portion 32 is referred to as the base side. In addition, of the four faces constituting the approximately rectangular cylindrical sleeve portion 32, the two faces that face each other in the circumferential direction C are referred to as circumferential side faces 321A, 321B, and the two faces that face each other in the direction of the motor shaft M0 are referred to as axial side faces 321C, 321D.

The first engaging portion 35 can engage with the coil 10. Specifically, as shown in Figs. 6(A), 6(D), and 6(E), the first engaging portion 35 has a first arm 351 and a claw 352 provided at its end. The first arm 351 is configured to bend elastically in the circumferential direction C (elastically deformable). Specifically, in this example, as shown in Figs. 6(A) and 6(D), the first arm 351 is a portion separated from the sleeve portion 32 in a tongue shape by a plurality of slits 34 provided on each of the circumferential side surfaces 321A and 321B of the sleeve portion 32. The slits 34 are provided by cutting out the sleeve portion 32 from the tip side toward the base end to a midpoint in the radial direction R where they do not reach the base end. In this example, four slits 34 are provided on each of the circumferential side surfaces 321A and 321B, and thus two first arms 351 are provided on each of the circumferential side surfaces 321A and 321B.

The four first arms 351 are configured as cantilevers integral with the sleeve portion 32 at the base end of the sleeve portion 32, with the tip end of the sleeve portion 32 being the free end. The first arms 351 form part of the insulating body portion 31 (and also serve as part of the insulating body portion 31), and at the tip end of the sleeve portion 32 the four first arms 351 are independent of one another and can elastically deform in the circumferential direction C. A claw 352 is provided at the tip of each first arm 351. As shown in Figures 6(A) and 6(E), the claw 352 has an inclined surface 353 that protrudes more from the tip end toward the base end, and an engagement surface 354 facing the radially outward RO.

The claws 352 on the circumferential side surface 321A and the claws 352 on the circumferential side surface 321B have engagement surfaces 354 that protrude outward from the first arm 351 in the circumferential direction C so that their inclined surfaces 353 are back-to-back with each other.

In this embodiment, the coil 10 is attached to the outside of the sleeve portion 32 as shown in FIG. 5. At this time, the engagement surface 354 of the claw 352 is configured to engage with the inner circumference of the coil 10 (specifically, the inner circumference of one revolution region CR on the radially inner side RI of the coil 10).

The second engagement portion 36 of the insulating member 30 can extend or protrude in the radial direction R of the stator 50 and engage with the core 51. Alternatively, the second engagement portion 36 can engage with a surface constituting the outer or inner circumference of the yoke portion 53. Specifically, as shown in Figs. 6(A), 6(D), and 6(E), the second engagement portion 36 has a second arm 361 and a claw 362 provided at its end. The second arm 361 is configured to bend elastically in the direction of the motor shaft M0 (elastically deformable). Specifically, in this example, the second arm 361 is a portion that extends or protrudes from the base end side of the axial side surfaces 321C and 321D of the insulating body portion 31, more specifically, the sleeve portion 32, via the flange portion 33 to the radially outer side RO, as shown in Figs. 6(A) and 6(D). In this example, two second arms 361 are provided approximately horizontally with the axial side surfaces 321C and 321D. The second arm 361 is a tongue-shaped member that protrudes in a cantilever state with the flange portion 33 at the base end, and the tip end is the free end, which is elastically deformable in the direction of the motor shaft M0. Also, a claw 362 is provided at the tip end of each second arm 361. As shown in FIG. 6(A) and FIG. 6(D), the claw 362 has an inclined surface 363 that protrudes more from the tip end toward the base end, and an engagement surface 364 facing the radially inward RI. The engagement surface 364 of the claw 362 on the axial side surface 321C and the claw 362 on the axial side surface 321D protrudes inward in the direction of the motor shaft M0 from the second arm 361 so that the inclined surfaces 363 of the claw 362 face each other.

In this embodiment, as shown in FIG. 5, the insulating member 30 is attached to the core member 52 so that the flange portion 33 and the inner surface 531 of the split yoke portion 53P face each other and the teeth portion 54 is housed in the sleeve portion 32. At this time, the engaging surface 364 of the claw 362 is configured to engage with the core 51 (more specifically, the recess 533 provided on the surface that constitutes the outer periphery of the approximately annular yoke portion 53).

<Manufacturing method (assembly method) of coil unit and stator>
A method for manufacturing the coil unit 20 will be described with reference to Fig. 7 to Fig. 9. Fig. 7 is a flow diagram showing an example of a method for manufacturing the coil unit 20. Figs. 8 and 9 are schematic diagrams showing an example of a method for manufacturing a coil unit in a time series. Fig. 8(A) is a side view of the coil 10 and the insulating member 30 as viewed from the circumferential direction C, and Fig. 8(B) is a schematic diagram showing the relationship between the insulating member 30 and the coil 10 in an engaged state, and is a plan view as viewed from the motor axis M0 direction. Figs. 8(C) to (E) are schematic plan views as viewed from the motor axis M0 direction showing the deformation state of the first engagement portion 35.

Figure 9 (A) is a side view of the insulating member 30 and the core member 52 as viewed from the circumferential direction C, and Figure 9 (B) is a schematic diagram showing the relationship between the insulating member 30 and the split yoke portion 53P in an engaged state, as viewed from the circumferential direction C. Figures 9 (C) to (E) are schematic side views as viewed from the circumferential direction C showing the deformed state of the second engaging portion 36.

First, the coil 10 is formed (Figure 7, step S1). For example, the coil 10 is formed by pressing the end faces of multiple strip-shaped conductor pieces (coil pieces) together and joining them to form a spiral structure. Alternatively, the spiral structure is formed by winding a long conductor wire (round wire, rectangular wire, etc.). The method of forming the coil 10 is not limited to this example, as long as it forms a spiral structure with concentrated windings.

Next, as shown in FIG. 8(A), the coil 10 is placed on the tip side of the sleeve portion 32 of the insulating member 30, and the coil 10 and the insulating member 30 are engaged (FIG. 7, step S3).

Here, as shown in FIG. 8(B), a predetermined clearance is ensured between the insulating member 30 and the coil 10, and the claws 352 are configured to be able to engage with the coil 10. Specifically, in the insulating member 30, in the two first arms 351 that are positioned opposite each other on the circumferential side surfaces 321A, 321B, the distance L1 between the outer sides in the circumferential direction C (the distance between the tips of the claws 352) is set to be smaller than the distance L2 in the circumferential direction C on the inner circumference of the coil 10.

On the other hand, the maximum separation distance (maximum protruding distance) L3 between the claws 352 (engagement surfaces 354) of the two opposing first arms 351 is set to be greater than the distance L2 in the circumferential direction C of the inner circumference of the coil 10.

In addition, the length L4 of the coil 10 in the radial direction R (thickness in the direction of the spiral axis) is set to be slightly smaller than the length L5 from the base end side (flange portion 33) of the first arm 351 to the engagement surface 354. Note that although the clearance between the coil 10 and the insulating member 30 is shown to be large in Figures 8(B) to 8(E), in reality, when the coil 10 and the insulating member 30 are engaged, the coil 10 is close (tight) to the insulating member 30 to the extent that movement (rattle) is not possible.

With this configuration, when the sleeve portion 32 is inserted into the inner circumference of the coil 10 from its tip side (claw 352 side) as shown in FIG. 8(C) and pushed from the radially outer side RO toward the radially inner side RI, the inclined surface 353 of the claw 352 gradually comes into contact with the inner circumference of the coil 10 as shown in FIG. 8(D), and the first arm 351 gradually elastically deforms so that the claw 352 approaches the circumferential direction C (toward the center of the spiral axis of the coil 10) as the inclined surface 353 protrudes. Then, when the claw 352 protrudes from the innermost one-turn region CRI of the coil 10 as shown in FIG. 8(E), the elastically deformed first arm 351 returns to its original state, and the engagement surface 354 of the claw 352 hooks and engages with the inner circumference of the innermost one-turn region CRI of the coil 10. In this way, the coil 10 and the first engagement portion 35 are engaged.

Next, as shown in FIG. 9(A), the insulating member 30 is placed on the tip side of the teeth portion 54, and the core 51 (core member 52) and the insulating member 30 are engaged (FIG. 7, step S5).

Here, as shown in FIG. 9(B), a predetermined clearance is ensured between the insulating member 30 and the core member 52 (split yoke portion 53P), and the claws 362 are configured to be able to engage with the split yoke portion 53P. Specifically, the two second arms 361 of the insulating member 30 have a distance L7 between their inner surfaces in the direction of the motor shaft M0 (distance between the tips of the claws 362) that is set to be greater than the length (height) L6 of the split yoke portion 53P in the direction of the motor shaft M0.

On the other hand, the minimum separation distance (maximum protruding distance) L8 between the two opposing claws 362 (engagement surfaces 364) is set to be smaller than the length L6 of the split yoke portion 53P in the motor shaft M0 direction.

Furthermore, the length (thickness) L9 in the radial direction R of the split yoke portion 53P (here, the thinnest part of the split yoke portion 53P, the shortest length from the extension line of the inner surface 531 to the recess 533, see FIG. 5(A)) is set to be slightly smaller than the length L10 from the base end side (flange portion 33) of the second arm 361 to the engagement surface 364. Note that although the clearance between the split yoke portion 53P and the insulating member 30 is shown large in FIGS. 9(B) to 9(E), in reality, when the split yoke portion 53P and the insulating member 30 are engaged, the split yoke portion 53P is close (tight) to the insulating member 30 to the extent that movement (rattle) is not possible.

With this configuration, as shown in FIG. 9(C), when the teeth 54 are inserted between the second arms 361 from their tip side and the core member 52 is pushed from the radial outside RO to the radial inside RI, the inclined surfaces 363 of the claws 362 come into contact with the upper and lower surfaces of the core 51 in the motor shaft M0 direction, respectively, as shown in FIG. 9(D), and the second arms 361 gradually deform elastically so that the two claws 362 move apart in the motor shaft M0 direction according to the amount of protrusion of the inclined surfaces 363. Then, as shown in FIG. 9(E), when the claws 362 protrude from the split yoke portion 53P (recess 533), the elastically deformed second arms 361 return to their original state, and the engagement surfaces 364 of the claws 362 hook and engage with the recesses 533 of the split yoke portion 53P. In this way, the coil 10, the insulating member 30 and the core member 52 are integrally engaged, and the coil unit 20 is assembled.

The insulating member 30 and the coil 10, and the insulating member 30 and the core member 52 have a minimum necessary clearance. The first arm 351 of the insulating member 30 elastically deforms when engaging with the coil 10. In other words, after the claw 352 engages with the coil 10, elastic deformation of the first arm 351 (elastic deformation toward the center of the spiral axis) is required to separate the insulating member 30 from the coil 10. However, after engaging the insulating member 30 and the coil 10, when the teeth portion 54 of the core member 52 is inserted into the sleeve portion 32 and the claw 362 is engaged with the core member 52, the elastic deformation of the first arm 351 is restricted in the sleeve portion 32. In other words, by engaging the insulating member 30 with the core member 52, it is possible to prevent the insulating member 30 from separating from the coil 10. In addition, the first engaging portion 35 and the second engaging portion 36 of the insulating member 30 can prevent the coil 10 from coming off the teeth portion 54 (moving in the radial direction R), and also restrict movement in the direction of the motor axis M0.

　Previously, to prevent the coil from coming off, it was necessary to fix a wedge plate 208 to the opening 207 of the slot 206, and the teeth 203 were provided with an engagement recess 203c for fixing the wedge plate 208. This resulted in a problem that the magnetic path became narrower near the engagement recess 203c, reducing the amount of magnetic flux and making it difficult to improve the motor characteristics. In addition, a process for attaching the insulating sheet 204, a process for attaching the coil 205, and a process for attaching the wedge plate 208 were required for each tooth 203, resulting in a large number of assembly steps, poor production efficiency, and a large number of parts.

According to this embodiment, a wedge plate that blocks the opening OP of the slot is not required, and there is no need to provide a recess in the teeth portion 54 to fix the wedge plate. This prevents the magnetic path in the teeth portion 54 from narrowing, improving motor performance. In addition, the insulating member 30, which is a resin molded product, is more rigid and easier to handle than an insulating sheet. Furthermore, since a single insulating member 30 can be used to provide the insulation means for the core 51 and the coil 10 and the means for preventing the coil 10 from coming off the core 51, the conventional wedge plate is not required. This improves the productivity of the stator, and therefore the productivity of the motor, and also makes it possible to reduce the number of parts.

Next, a method for manufacturing the stator 50 will be described with reference to FIG. 10. FIG. 10 is an external perspective view showing the manufacturing method for the stator 50 in chronological order. The manufacturing method for the stator 50 of this embodiment uses the insulating member 30 of this embodiment described above, and after engaging the coil 10 with the first engaging portion 35 of the insulating member 30, engages the core 51 with the second engaging portion 36 of the insulating member 30.

Specifically, as shown in FIG. 8, the sleeve portion 32 of the insulating member 30 is inserted into the inner circumference of the coil 10, and the inner circumference of the coil 10 and the claw 352 of the first engaging portion 35 are engaged. Next, as shown in FIG. 9, the core member 52 constituting the core 51 are engaged with the insulating member 30. In particular, the split yoke portion 53P (recess 533) of the core member 52 is engaged with the claw 362 of the second engaging portion 36.

In this way, the coil unit 20 is assembled. As shown in FIG. 10(A), multiple coil units 20 are prepared and arranged in a ring shape (FIG. 10(B)). At this time, a positioning means of a jig (not shown) is engaged with the recesses 533 of the split yoke portion 53P (for example, near the center of the recesses 533 in the direction of the motor shaft M0) to position each coil unit 20 in the circumferential direction C. The coil units 20 are then fixed by tight fitting or the like. In this way, a substantially annular core 51 is formed by the multiple core members 52. In detail, the substantially annular yoke portion 53 is formed by the split yoke portion 53P, and the outer periphery of the substantially annular yoke portion 53 is formed by the outer surface 532 of the split yoke portion 53P. In this way, the stator 50 shown in FIG. 2 is assembled.

In this manner, in this embodiment, the second engagement portion 36 (claw 362) of the insulating member 30 is engaged using the recess 533 that engages the positioning means when arranging the coil units 20 in a ring shape (it also serves as the recess 533). Therefore, there is no need to create a new core 51 (core member 52) to fasten the insulating member 30 of this embodiment, and the insulating member 30 can be easily fastened to a conventional core 51.

The above has been explained using an example of a stator 50 used in an inner rotor type motor, but it can also be implemented in an outer rotor type motor.

Second Embodiment
A second embodiment will be described with reference to Figures 11 to 13. The second embodiment is an example of a case in which the insulating member 30 of the present invention is applied to a stator 50 employed in an outer rotor type motor.

Figure 11 (A) is a schematic diagram showing a portion of an outer rotor type core 51, and is a plan view seen from the motor shaft M0 direction. In this case, the core 51 is made up of a substantially annular (undivided) yoke portion 53 and multiple core members 52 that are substantially I-shaped in plan view. The core members 52 are teeth portions 54, and have notch portions 58 that protrude in the motor shaft M0 direction on the radially inner side RI. The yoke portions 53 have grooves 59 on their outer circumferential surface. Each groove 59 is cut in the motor shaft M0 direction, and multiple grooves are arranged at equal intervals in the circumferential direction C. Additionally, multiple recesses 533 are provided on the inner circumferential surface of the yoke portions 53, spaced a predetermined distance apart in the circumferential direction C.

FIG. 11(B) is a side view of the insulating member 30 as viewed from the circumferential direction C (a side view corresponding to FIG. 6(D)), and FIG. 11(C) is a plan view of the insulating member 30 as viewed from the direction of the motor shaft M0 (a plan view corresponding to FIG. 6(E)).

The first engagement portion 35 is similar to that of the first embodiment and is capable of engaging with the inner circumference of the coil 10. In this case, the second engagement portion 36 is provided on one side (here, the upper side) of the flange portion 33 in the direction of the motor shaft M0. The second engagement portion 36 extends or protrudes radially inward RI from the flange portion 33 as its base end. In addition, the claw 352 of the first engagement portion 35 is located on the radial outside RO, and the claw 362 of the second engagement portion 26 is located on the radial inside RI. The rest of the configuration is similar to that of the first embodiment.

With reference to Figure 12, a method of manufacturing the coil unit 20 in the second embodiment will be described. Figures 12(A), 12(B), 12(D), and 12(E) are plan views of the coil 10 and the insulating member 30 as viewed from the direction of the motor shaft M0. Figure 12(C) is a side view of Figure 12(B) as viewed from the circumferential direction C (to the right of Figure 12(B)), and Figure 12(F) is a side view of Figure 12(D) as viewed from the circumferential direction C (to the right of Figure 12(D)).

First, the coil 10 is attached to the outside of the sleeve portion 32 as shown in FIG. 12(A). Specifically, the sleeve portion 32 is inserted into the inner circumference of the coil 10 (spiral structure) from its tip side (the claw 352 side of the first engagement portion 35), and the coil 10 is pushed from the radial outside RO to the radial inside RI. As in the first embodiment, the first arm 351 of the first engagement portion 35 gradually elastically deforms toward the center of the spiral axis of the coil 10. When the claw 352 protrudes from the coil 10, the elastically deformed first arm 351 returns to its original state, and the engagement surface 354 of the claw 352 hooks and engages with the inner circumference of the outermost one-turn region CRO of the coil 10. In this way, the coil 10 and the first engagement portion 35 are engaged as shown in FIG. 12(B) and FIG. 12(C).

Next, the core member 52 (teeth portion 54) is attached to these. Specifically, as shown in FIG. 12(D), the notch portion 58 of the teeth portion 54 and the claws 352 of the first engagement portion 35 are positioned to face each other, and the teeth portion 54 is inserted into the inside of the sleeve portion 32 from the notch portion 58 side and pushed in the radial direction R. In this way, the coil unit 20 is assembled, with the insulating member 30 interposed between the coil 10 and the core member 52 (teeth portion 54) as shown in FIG. 12(E) and (F).

In the second embodiment, the coil unit 20 is fixed to the substantially annular yoke portion 53, i.e., the stator 50 is assembled, so that the coil 10, insulating member 30 and core 51 are integrally engaged.

The manufacturing method of the stator 50 will be described with reference to Figure 13. Figures 13(A) and 13(B) are plan views of the core 51 and the stator 50 as viewed from the direction of the motor shaft M0. Figure 13(C) is a cross-sectional view taken along line a-a in Figure 13(B). Figure 13(D) is a cross-sectional view taken along a plane perpendicular to the motor shaft M0 (plane b shown in Figure 13(C)).

As shown in FIG. 13(A), the yoke portion 53 has a groove 59 on its outer circumferential surface. The notch portion 58 of the coil unit 20 (including the teeth portion 54) is engaged with this groove 59 from above the motor shaft M0 and pushed in the direction of the motor shaft M0.

As a result, the teeth portion 54 of the coil unit 20 engages with the yoke portion 53 as shown by the dashed line in FIG. 2B, and the coil unit 20 is fixed to the yoke portion 53.

In this example, the second engagement portion 36 is provided only above the flange portion 33 in the motor shaft M0 direction (FIG. 12(F)), and does not interfere with the operation of inserting the notch portion 58 into the recessed groove 59. When the coil unit 20 is fixed to the yoke portion 53, the second arm 361 of the second engagement portion 36 crosses the yoke portion 53, and the engagement surface 364 of the claw 362 hooks onto and engages with the recess 533 provided on the surface (inner surface 53I) that constitutes the inner circumference of the yoke portion 53. In other words, in this case as well, after the coil 10 and the first engagement portion 35 are engaged, the core 51 and the second engagement portion 36 are engaged. In this way, the coil 10, the insulating member 30 and the core 51 are engaged together, and the stator 50 is assembled.

As in the first embodiment, the size and shape of the first engagement portion 35 of the insulating member 30 are appropriately selected so that the claws 352 can engage with the inner circumference of the coil 10 and prevent it from coming off. The size and shape of the second engagement portion 36 are appropriately selected so that it can prevent the coil 10 (coil unit 20) from coming off the yoke portion 53 (movement in the radial direction R).

Here, an outer rotor type stator 50 has been described as an example, but the second embodiment can also be applied to an inner rotor type stator. In that case, the grooves 59 of the yoke portion 53 are provided on the inner peripheral surface 53I of the yoke portion 53 at a predetermined distance apart in the circumferential direction C. Furthermore, the inner peripheral surface 53I of the yoke portion 53 has a plurality of recesses 533 provided thereon at a predetermined distance apart in the circumferential direction C. The engagement surface 364 of the claw 362 of the second engagement portion 36 hooks onto and engages with the recesses 533 provided on the inner peripheral surface 53I of the yoke portion 53. Note that the inner peripheral surface 53I may not have the recesses 533, and the claws 362 may engage with the inner peripheral surface 53I.

Third Embodiment
A third embodiment will be described with reference to Figures 14 to 16. The third embodiment is another example of a case in which the insulating member 30 of the present invention is applied to a stator 50 employed in an outer rotor type motor.

FIG. 14(A) is a schematic diagram showing a portion of the core 51, and is a plan view seen from the direction of the motor shaft M0. In this case, the core 51 has a substantially annular (non-split) yoke portion 53 and a number of teeth portions 54 that protrude radially outward RO from the yoke portion 53. This is a non-split type core 51 in which the yoke portion 53 and the multiple teeth portions 54 are integrally formed.

FIG. 14(B) is a side view of the insulating member 30 as viewed from the circumferential direction C (a side view corresponding to FIG. 6(D)), and FIG. 13(C) is a plan view of the insulating member 30 as viewed from the direction of the motor shaft M0 (a plan view corresponding to FIG. 6(E)).

The insulating member 30 has an insulating main body 31, a first engaging portion 35, and a second engaging portion 36, which are molded integrally from an insulating resin material to form a resin molded body, and is capable of insulating the core 51 from the coil 10. It is the same as the first embodiment, except that the claw 352 of the first engaging portion 35 is located on the radial outside RO and the claw 362 of the second engaging portion 26 is located on the radial inside RI.

A method of manufacturing the stator 50 in the third embodiment will be described with reference to Figs. 15 and 16. Figs. 15(A) and 15(B) are plan views of the coil 10 and the insulating member 30 as viewed from the motor axis M0 direction. Fig. 15(C) is a side view of Fig. 15(B) as viewed from the circumferential direction C (to the right of Fig. 15(B)). Figs. 16(A), 16(C), and 16(E) are plan views of the coil 10 and the insulating member 30 as viewed from the motor axis M0 direction. Fig. 16(B) is a side view of Fig. 16(A) as viewed from the circumferential direction C (to the right of Fig. 16(A)). Fig. 16(D) is a cross-sectional view taken along the line c-c in Fig. 16(C). Fig. 16(E) is a cross-sectional view taken along a plane perpendicular to the motor axis M0 (plane d shown in Fig. 16(D).

First, the coil 10 is attached to the outside of the sleeve portion 32 as shown in FIG. 15(A). Specifically, the sleeve portion 32 is inserted into the inner circumference of the coil 10 (spiral structure) from its tip side (the claw 352 side of the first engagement portion 35), and the coil 10 is pushed from the radial outside RO to the radial inside RI. As in the first embodiment, the first arm 351 of the first engagement portion 35 gradually elastically deforms toward the center of the spiral axis of the coil 10. When the claw 352 protrudes from the outermost one-turn region CRO of the coil 10, the elastically deformed first arm 351 returns to its original state, and the engagement surface 354 of the claw 352 hooks and engages with the inner circumference of the outermost one-turn region CRO of the coil 10. In this way, the coil 10 and the first engagement portion 35 are engaged as shown in FIG. 15(B) and FIG. 15(C).

These are then attached to the teeth portion 54 of the core 51. Specifically, as shown in Figures 16(A) and 16(B), the second engagement portion 36 of the insulating member 30 is opposed to the radially outer side RO of the teeth portion 54, and the teeth portion 54 is inserted into the sleeve portion 32 and pushed in the radial direction R. This causes the teeth portion 54 to pass through the inside of the sleeve portion 32 as shown in Figures 16(C) and 16(D).

At this time, the inclined surfaces 363 of the second arm claws 362 contact the upper and lower surfaces of the core 51 in the motor shaft M0 direction, respectively, and the second arm 361 gradually elastically deforms so that the two claws 362 move apart in the motor shaft M0 direction. When the claws 362 protrude from the yoke portion 53, the elastically deformed second arm 361 returns to its original state, and the engagement surface 364 of the claws 362 hooks onto and engages with the recesses 533 in the inner circumferential surface 53I of the yoke portion 53. In this way, the coil 10, the insulating member 30, and the core member 52 are integrally engaged (FIG. 16(D)). Note that in this case as well, the inner circumferential surface 53I of the yoke portion 53 may not be provided with recesses 533, and the claws 362 may engage with the inner circumferential surface 53I.

In other words, in this case too, the coil 10 is engaged with the first engagement portion 35, and then the core 51 is engaged with the second engagement portion 36. In this way, the coil 10, the insulating member 30 and the core 51 are integrally engaged, and the stator 50 is assembled.

The size and shape of the first engagement portion 35 of the insulating member 30 are appropriately selected so that the claws 352 can engage with the inner circumference of the coil 10 and prevent it from coming off, and the size and shape of the second engagement portion 36 are appropriately selected so that they can prevent the coil 10 from coming off (moving in the radial direction R) from the yoke portion 53 (teeth portion 54).

Here, an outer rotor type stator 50 has been described as an example, but the second embodiment can also be applied to an inner rotor type stator (a stator having a core 51 in which the teeth portion 54 protrudes radially inward RI from the inner circumferential surface of the yoke portion 53 as its base end).

The motor 100 shown in Figure 1 is constructed by incorporating the stator 50 described in the above embodiment.

According to this embodiment, the coil 10 can be fixed to the core 51 (yoke portion 53, teeth portion 54) without narrowing the magnetic path of the core 51, making it possible to fully utilize the performance of the motor.

In addition, the configuration for insulating the coil 10 and the core 51 and the assembly steps for the stator 50 can be simplified, and the number of parts can be reduced. This improves the productivity of the stator 50 and, ultimately, the motor 100.

In the above embodiment, the coil 10 is described as a spiral structure in which the conductor is coated with insulating resin. However, the coil 10 may be a coil in which the spiral structure is formed from a conductor that is not coated with insulating resin, and an insulating resin layer is provided to cover the entire spiral structure and insulate the regions CR of the spiral structure for one revolution. In this case, the insulating resin layer is formed, for example, by injection molding of insulating resin.

Furthermore, the configuration of the first engaging portion 35 and the second engaging portion 36 is not limited to the above example, as long as the configuration can fix the coil 10 to the core 51 without narrowing the magnetic path of the core 51.

The present invention is not limited to the above-mentioned embodiments, but can be configured in various other embodiments.

REFERENCE SIGNS LIST 10 Coil 20 Coil unit 30 Insulating member 31 Insulating body 32 Sleeve 33 Flange 34 Slit 35 First engaging portion 36 Second engaging portion 50 Stator 51 Core 52 Core member 53 Yoke 53P Split yoke 54 Teeth 58 Notch 59 Groove 70 Rotor 71 Magnet 80 Shaft 82 Bearing 90 Case (housing)
100 Motor 321A, 321B Circumferential side surface 321C, 321D Axial side surface 321D Axial side surface 351 First arm 352 Claw 353 Inclined surface 354 Engagement surface 361 Second arm 362 Claw 363 Inclined surface 364 Engagement surface 531 Inner surface 532 Outer surface 533 Recess

Claims

An insulating member capable of insulating a stator core from a coil that can be attached to the core,
an insulating body portion disposed between the coil and the core;
A first engagement portion capable of engaging with the coil;
a second engaging portion extending or protruding from the insulating body portion in a radial direction of the stator and capable of engaging with the core;
An insulating member characterized by:
An insulating member capable of insulating a stator core from a coil that can be attached to the core,
an insulating body portion disposed between the coil and the core;
A first engagement portion capable of engaging with the coil;
a second engaging portion that can engage with a surface that constitutes an outer periphery or an inner periphery of the substantially annular yoke portion of the core;
An insulating member characterized by:
The first engagement portion and the insulating main body portion are integrally molded from a resin material.
The insulating member according to claim 1 or 2.
3. The insulating member according to claim 1, wherein the second engaging portion and the insulating body portion are integrally formed from a resin material.
the insulating body portion has a sleeve portion disposed on the outer side of the teeth portion of the core and a flange portion provided around one opening of the sleeve portion,
the first engagement portion includes a claw provided in a part of the other opening of the sleeve portion and capable of engaging with an inner periphery of the coil,
The second engagement portion includes an arm portion extending or projecting in a direction away from the first engagement portion, and a claw provided at a tip of the arm portion and capable of engaging with the core.
The insulating member according to claim 1 or 2.
The coil is a concentrated winding coil having a spiral structure formed by continuously overlapping a conductor that goes around the outside of one of the teeth portions.
The insulating member according to claim 5 .
The insulating member according to claim 1 or 2;
A core member constituting the core;
The coil is integrally engaged with the
A coil unit characterized by:
A stator in which the insulating member according to claim 1 or 2 is interposed between the coil and the core.
A motor having the stator according to claim 8.
A method for manufacturing a stator using the insulating member according to claim 1 or 2, comprising the steps of:
After the coil is engaged with the first engaging portion, the core is engaged with the second engaging portion.
A method for manufacturing a stator comprising the steps of: