Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K3/00—Details of windings
  • H02K3/46—Fastening of windings on the stator or rotor structure

Definitions

• the technology disclosed herein relates to a stator.
• a stator In the technical field of stators, a stator is known that includes a stator core with multiple radially extending teeth, an insulating film attached to the stator core, and a winding wound around the multiple teeth with the insulating film interposed between them (see, for example, JP 2018-198515 A). This stator is said to improve assembly ease and insulation reliability.
• the technology disclosed herein provides a stator that can reduce stray capacitance.
• a stator comprises a stator core having a plurality of radially extending teeth, a resin insulator attached to the stator core, and a winding wound around the plurality of teeth via the insulator.
• the insulator has a mounting portion attached to the mounting surface of the stator core, and a groove formed in the mounting portion that opens toward the mounting surface, and a gas layer is formed between the stator core and the winding by the groove.
• the technology disclosed herein provides a stator that can reduce stray capacitance.
• FIG. 2 is a plan view of a stator according to an embodiment of the technology of the present disclosure.
• FIG. 2 is a plan view of a stator component.
• FIG. 3 is an enlarged view of part A in FIG. 2 .
• FIG. 3 is a further enlarged view of part A in FIG. 2.
• FIG. FIG. FIG. 2 is a two-sided view of the first insulator.
• FIG. 10 is an explanatory diagram illustrating stray capacitance.
• FIG. 10 is an enlarged view of a main part of a stator component according to a first modified example.
• FIG. 10 is a vertical cross-sectional view of a first insulator according to a first modified example.
• FIG. 10 is a vertical cross-sectional view of a first insulator according to a first modified example.
• FIG. 10 is an enlarged view of a main part of a stator component according to a second modified example.
• FIG. 11 is an enlarged view of a main part of a stator component according to a third modified example.
• FIG. 10 is a perspective view of a stator component according to a fourth modified example.
• FIG. 13 is a perspective view of a stator component according to a fifth modified example.
• FIG. 13 is a perspective view of a first insulator according to a sixth modified example.
• FIG. 13 is a plan view of a first insulator according to a sixth modified example.
• FIG. 13 is a perspective view of a first insulator according to a seventh modified example.
• the stator 10 includes a plurality of stator components 12.
• the stator 10 is formed by combining a plurality of stator components 12 in an annular shape.
• FIG. 1 shows the configuration of half of the stator 10.
• the stator 10 is applied to a brushless motor.
• Brushless motors may be used for any purpose. Examples of brushless motors include fan motors, pump drive motors, and compressor motors.
• the X direction indicates the tangential direction of the stator 10
• the Y direction indicates the radial direction of the stator 10
• the Z direction indicates the axial direction of the stator 10.
• the circumferential direction of the stator 10 refers to the direction around the central axis of the stator 10.
• the tangential direction, radial direction, axial direction, and circumferential direction of the stator core 24, which will be described later, are the same directions as the tangential direction, radial direction, axial direction, and circumferential direction of the stator 10, respectively.
• each stator component 12 includes a core member 14, an insulator 16, and a winding winding portion 18.
• the core member 14 has a teeth portion 20 and a core back portion 22.
• the core back portion 22 extends in the circumferential direction of the stator core 24 (see Figure 1), and the teeth portion 20 extends from the center of the core back portion 22 inward in the Y direction.
• the tip portions of the teeth portions 20 are free ends, and the base ends of the teeth portions 20 are connected to the core back portion 22.
• the stator core 24 (see Figure 1) is formed by combining multiple core members 14 in an annular shape.
• the multiple core back portions 22 form an annular portion 26 (see Figure 1) that is the outer periphery of the stator core 24, and the multiple tooth portions 20 extend radially from the center of the stator core 24. Slots 28 are formed between the multiple tooth portions 20.
• the insulator 16 is attached to the core member 14.
• the insulator 16 is made of resin. Examples of resins that can be used to form the insulator 16 include polyimide, polyamide, polyphenylene sulfide (PPS), and polybutylene terephthalate (PBT). Any resin can be used to form the insulator 16.
• the insulator 16 has a side wall portion 30 and an inner wall portion 32.
• the side wall portion 30 is attached to the side surface 20A and covers the side surface 20A.
• the inner wall portion 32 is attached to the inner surface 22A and covers the inner surface 22A.
• the side wall portion 30 and the inner wall portion 32 are arranged in a slot 28.
• the side surface 20A and the inner surface 22A are an example of a "mounting surface” according to the present disclosure.
• the side wall portion 30 and the inner wall portion 32 are an example of a “mounting portion” according to the present disclosure.
• the side wall portion 30 is an example of a "first mounting portion” according to the present disclosure
• the inner wall portion 32 is an example of a "second mounting portion” according to the present disclosure.
• the side wall portion 30 has an opposing surface 30A facing the side surface 20A
• the inner wall portion 32 has an opposing surface 32A facing the inner surface 22A.
• a first groove 34 is formed in the opposing surface 30A of the side wall portion 30, and a second groove 36 is formed in the opposing surface 32A of the inner wall portion 32.
• the first groove 34 opens to the side surface 20A
• the second groove 36 opens to the inner surface 22A.
• two first grooves 34 are formed in the opposing surface 30A of the side wall portion 30.
• the two first grooves 34 are aligned in the Y direction.
• one second groove 36 is formed in the opposing surface 32A of the inner wall portion 32.
• the first groove 34 and the second groove 36 are an example of a "groove” according to the present disclosure.
• the first gas layer 38 and the second gas layer 40 are an example of a "gas layer” according to the present disclosure.
• the side wall portion 30 has an abutment portion 42.
• the abutment portion 42 is formed adjacent to the first groove 34 and abuts against the side surface 20A.
• the inner wall portion 32 has an abutment portion 44.
• the abutment portion 44 is formed adjacent to the second groove 36 and abuts against the inner surface 22A.
• the abutment portion 42 formed on the side wall portion 30 includes a first abutment portion 46 formed at one end of the side wall portion 30 in the Y direction, which is the extension direction of the teeth portion 20, a second abutment portion 48 formed at the other end of the side wall portion 30 in the Y direction, and a third abutment portion 50 formed in the center of the side wall portion 30 in the Y direction.
• the multiple winding portions 52 of the first turn of the winding winding portion 18 located on the side wall portion 30 side are aligned in the Y direction, which is the extension direction of the tooth portion 20.
• the multiple winding portions 52 have extended winding portions 52A located on an extension line L, which is an extension of the boundary line between the first groove 34 and the abutment portion 42 in the normal direction of the side surface 20A of the tooth portion 20.
• the multiple winding portions 52 are aligned so that the apex 52A1 of the extended winding portion 52A on the side wall portion 30 side is located on the extension line L.
• the apex 52A1 of the extended winding portion 52A is the contact point that comes into contact with the side wall portion 30.
• the abutment portion 44 formed on the inner wall portion 32 has a first abutment portion 54 formed at one end of the inner wall portion 32 in the X direction, and a second abutment portion 56 formed at the other end of the inner wall portion 32 in the X direction.
• the insulator 16 is composed of a first insulator 58 and a second insulator 60 that are divided in the Z direction.
• the dividing portion 62 that divides the first insulator 58 and the second insulator 60 in the Z direction is located, for example, in the center of the tooth portion 20 in the Z direction.
• the first insulator 58 and the second insulator 60 are connected at the dividing portion 62.
• the winding portion 18 has an axial wiring portion 64 that is wired in the Z direction along the side wall portion 30 of the tooth portion 20 (see Figure 6), a coil end portion 66 that is wired on one side of the tooth portion 20 in the Z direction, and a coil end portion 68 that is wired on the other side of the tooth portion 20 in the Z direction.
• the first insulator 58 has a coil end insulating portion 70.
• the coil end insulating portion 70 connects one end of the pair of side wall portions 30 in the Z direction.
• the coil end insulating portion 70 is disposed between the tooth portion 20 and the coil end portion 66 (see FIG. 5), and insulates the tooth portion 20 from the coil end portion 66.
• a positioning portion 72 is formed at the connection (corner) between the coil end insulating portion 70 and the side wall portion 30.
• the positioning portion 72 is formed by uneven portions repeatedly arranged in the Y direction.
• the positioning portion 72 positions the multiple winding portions 52 (see Figure 4) of the first turn of the winding winding portion 18, so that, as described above, the multiple winding portions 52 are aligned so that the apex 52A1 of the extended winding portion 52A on the side wall portion 30 side is located on the extension line L.
• the first groove 34, second groove 36, abutment portion 42, and abutment portion 44 described above extend in the Z direction and reach the dividing portion 62.
• the second insulator 60 has the same configuration as the first insulator 58, and its description will be omitted.
• Stray capacitance refers to the capacitance component generated by the potential difference between the winding winding portion 18 and the stator core 24.
• the stray capacitance is calculated using the following theoretical formula.
• the relative permittivity refers to the relative permittivity of the insulator 16
• the surface area refers to the surface area of the stator core 24, and the distance refers to the distance between the stator core 24 and the winding winding portion 18.
• a first gas layer 38 is formed by the first groove 34 between the tooth portion 20 and the winding portion 18 in the X direction. Therefore, the first gas layer 38 can lower the relative dielectric constant, thereby reducing the stray capacitance between the tooth portion 20 and the winding portion 18.
• a second gas layer 40 is formed by the second groove 36 between the core back portion 22 and the winding portion 18 in the Y direction. Therefore, the second gas layer 40 can lower the relative dielectric constant, thereby reducing the stray capacitance between the core back portion 22 and the winding portion 18.
• the stray capacitance between the winding portion 18 and the stator core 24 can be reduced, eliminating the need to install a noise-cutting filter in the inverter. This helps prevent costs from increasing.
• a first gas layer 38 is formed between the teeth portion 20 and the winding portion 18, and a second gas layer 40 is formed between the core back portion 22 and the winding portion 18. This reduces the stray capacitance between the stator core 24 and the winding portion 18, both between the teeth portion 20 and the winding portion 18 and between the core back portion 22 and the winding portion 18, compared to when only one of the first gas layer 38 and the second gas layer 40 is formed.
• the thickness of the side wall portion 30 can be made thinner than when the tooth portion 20 and the winding portion 18 are insulated only by the side wall portion 30.
• a second gas layer 40 between the core back portion 22 and the inner wall portion 32 by the second groove 36 the thickness of the inner wall portion 32 can be made thinner than when the core back portion 22 and the winding portion 18 are insulated only by the inner wall portion 32. This allows the cross-sectional area of the slot 28 to be increased, and therefore the number of turns of the winding portion 18 can be increased, thereby preventing the stator 10 from becoming larger. In other words, it is possible to prevent the stator 10 from becoming larger in size in order to increase the cross-sectional area of the slot 28.
• the side wall portion 30 has a first abutment portion 46 formed at one end of the side wall portion 30 and a second abutment portion 48 formed at the other end of the side wall portion 30, and the first abutment portion 46 and the second abutment portion 48 abut against the side surface 20A of the tooth portion 20.
• the side wall portion 30 is supported by the side surface 20A of the tooth portion 20 at one end and the other end, thereby suppressing rattling of the insulator 16 relative to the stator core 24.
• the side wall portion 30 has a third abutment portion 50 formed in the center of the side wall portion 30, which abuts against the side surface 20A of the tooth portion 20.
• the side wall portion 30 is supported at its center by the side surface 20A of the tooth portion 20, so that even when a first groove 34 is formed in the side wall portion 30, the tightening force of the winding winding portion 18 can be prevented from causing the side wall portion 30 to bend toward the side surface 20A.
• the first groove 34 opens on the side surface 20A of the tooth portion 20, rather than on the side surface of the winding portion 18. Therefore, the winding portion 18 can be supported on the flat surface of the side wall portion 30 on the winding portion 18 side, preventing the winding portion 18 from deforming toward the side surface 20A.
• the inner wall portion 32 has a first abutment portion 54 formed at one end of the inner wall portion 32 and a second abutment portion 56 formed at the other end of the inner wall portion 32, and the first abutment portion 54 and the second abutment portion 56 abut against the inner surface 22A of the core back portion 22.
• the inner wall portion 32 is supported at one end and the other end by the inner surface 22A of the core back portion 22, thereby suppressing rattling of the insulator 16 relative to the stator core 24.
• the multiple winding portions 52 of the first turn located on the side wall portion 30 side of the winding winding portion 18 have extended winding portions 52A located on an extension line L extending the boundary line between the first groove 34 and the abutment portion 42 in the normal direction of the side surface 20A of the tooth portion 20, and the top 52A1 on the side wall portion 30 side of the extended winding portion 52A is located on the extension line L. Therefore, for the top 52A1 of the extended winding portion 52A, which is close to the tooth portion 20, the boundary between the first groove 34 and the abutment portion 42 is allocated as an insulating portion.
• the stray capacitance between the tooth portion 20 and the extended winding portion 52A can be reduced.
• a first gas layer 38 is formed between the teeth portion 20 and the winding portion 18, and a second gas layer 40 is formed between the core back portion 22 and the winding portion 18, but either the first gas layer 38 or the second gas layer 40 may be omitted.
• the insulator 16 is composed of a first insulator 58 and a second insulator 60 separated in the Z direction.
• the insulator 16 may be configured such that the first insulator 58 and the second insulator 60 are integrated, i.e., formed in a ring shape around the tooth portion 20.
• the tooth portion 20 may be formed in a straight shape in the Y direction (i.e., a cross section with a constant shape in the Y direction) so that the tooth portion 20 can be inserted inside the insulator 16.
• a third abutment portion 50 is formed in the center of the side wall portion 30, and first grooves 34 are formed on both sides of the third abutment portion 50 on the opposing surface 30A of the side wall portion 30.
• the third abutment portion 50 may be omitted from the center of the side wall portion 30, and only one first groove 34 may be formed on the opposing surface 30A of the side wall portion 30.
• the width of the third abutment portion 50 along the Y direction is set to be the same as the width (diameter) of one winding portion 52 (see Figure 4), but as shown in Figure 11, it may also be set to be the same as the width of multiple winding portions 52. Note that in the example shown in Figure 11, the width of the third abutment portion 50 along the Y direction is set to be the same as the width of two winding portions 52.
• the multiple winding portions 52 are aligned so that the apex 52A1 on the side wall portion 30 side of the extended winding portion 52A is positioned on the extension line L.
• the multiple winding portions 52 may all be aligned so that their apex is offset from the extension line L.
• the insulator 16 is composed of a first insulator 58 and a second insulator 60 that are divided in the Z direction, and the first insulator 58 and the second insulator 60 are connected at the dividing portion 62.
• the first insulator 58 and the second insulator 60 may be separated in the Z direction.
• the first insulator 58 and the second insulator 60 may be configured to be attached to both ends of the core member 14 in the Z direction.
• the insulator 16 has a coil end insulating portion 70 arranged between the tooth portion 20 and the coil end portion 66.
• the coil end insulating portion 70 may have an opening 74 that opens in the Z direction.
• the opening 74 may penetrate in the Z direction, or may be formed in a concave shape that opens only on one side or the other side in the Z direction.
• a positioning portion 72 is formed at the connection portion between the coil end insulating portion 70 and the side wall portion 30.
• the positioning portion 72 may be omitted from the connection portion (corner portion) between the coil end insulating portion 70 and the side wall portion 30.
• the stator of claim 1 (Appendix 3)
• the first mounting portion has an abutment portion (42) formed adjacent to the first groove and abutting against a side surface of the tooth portion,
• the abutment portion has a first abutment portion (46) formed at one end of the first mounting portion in the extension direction of the tooth portion, and a second abutment portion (48) formed at the other end of the first mounting portion in the extension direction of the tooth portion.
• the stator of claim 2. (Appendix 4)
• the abutment portion has a third abutment portion (50) formed in a central portion of the first mounting portion in the extension direction of the teeth portion. 4.
• the plurality of winding portions (52) of the first windings located on the first mounting portion side of the winding winding portion are aligned in the extension direction of the teeth portion,
• the plurality of winding portions include an extension winding portion (52A) located on an extension line (L) obtained by extending a boundary line between the first groove and the abutment portion in a normal direction to a side surface of the tooth portion,
• the top portion (52A1) of the extension winding portion on the first mounting portion side is located on the extension line. 5.
• the winding portion has a coil end portion (66) that is wired on one axial side of the stator core relative to the tooth portion,
• the insulator has a coil end insulating portion (70) arranged between the tooth portion and the coil end portion,
• the coil end insulating portion has an opening (74) that opens in the axial direction of the stator core. 6.
• the stator according to any one of claims 1 to 5.

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• Engineering & Computer Science (AREA)
• Power Engineering (AREA)
• Insulation, Fastening Of Motor, Generator Windings (AREA)

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Citations (4)

• 2024
  • 2024-02-02 JP JP2024015189A patent/JP2025120005A/ja active Pending
  • 2024-12-02 WO PCT/JP2024/042554 patent/WO2025164077A1/ja active Pending

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