JP2009261086A - Stator and method for manufacturing stator - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a stator which absorbs dimensional variation of a coil and a core while eliminating the gap between them by integrally resin molding the coil and core, and enhances heat dissipation properties and manufacturing efficiency, and to also provide a method for manufacturing a stator. <P>SOLUTION: In a stator constituted by fitting a coil 10 and a core 20, the coil 10 and core 20 are molded integrally by carrying out resin molding at least between the coil 10 and core 20 and the coil side end face 14. Alternatively, the coil 10 and core 20 are molded integrally by injecting resin 30 at least between the coil 10 and core 20 and to the coil side end face 14 while the coil 10 and core 20 are fitted in a die. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a stator formed by integrally forming a coil and a core with a resin, and a method for manufacturing the stator.

Conventional stators in which a coil and a core are fitted together use an insulator for insulation between the coil and the core. There exists following patent document 1 as such a thing. Patent Document 1 below is an invention relating to an insulator and a motor including the insulator, and discloses a technique in which the insulator is shaped so as not to cause coil collapse.
JP 2004-72970 A

The invention shown in Patent Document 1 has an advantage that coil collapse can be prevented.
However, there has been a problem that no measures have been taken regarding the heat dissipation of the stator. That is, as in the invention shown in Patent Document 1, in a stator using an insulator for insulation between a coil and a core, it is common to provide a taper on the insulator in order to ensure the releasability from the mold of the insulator. there were. Therefore, there is a problem that there is a gap between the core and the insulator, and the heat dissipation of the stator is poor. Also, from the viewpoint of the space factor of the stator and heat dissipation, the insulator is generally formed thin. Therefore, when the insulator is fitted to the core, a crack or the like enters the thin insulator and damages the insulating coating of the core. There was a problem.
Conventionally, the core is generally configured by laminating thin electromagnetic steel sheets. Such cores have the problem that the dimensions are not constant due to variations in the thickness of the electromagnetic steel sheets and the wear of the cutting blades of the punching die, and there is a gap between the core and the insulator, resulting in poor heat dissipation of the stator. It was.

  Accordingly, the present invention solves the above-described conventional problems, and by integrally forming the coil and the core with a resin, there is no gap between the coil and the core and absorbs the dimensional variation of the coil and the core. It is an object to provide a stator and a method for manufacturing a stator that can improve heat dissipation and improve manufacturing efficiency.

  The stator of the present invention is a stator in which a coil and a core are fitted together, and the coil and the core are integrally formed by resin molding at least between the coil and the core and the coil side end face. One feature.

  According to the first feature of the present invention, the stator is formed by fitting the coil and the core, and the coil and the core are integrally formed by resin molding at least between the coil and the core and the coil side end face. Therefore, the stator itself can be manufactured by integrally forming the coil and the core with a resin mold. Therefore, a stator with good manufacturing efficiency can be obtained. Further, by resin molding between the coil and the core, the coil and the core can be insulated and the space between the coil and the core can be filled with resin. Therefore, there is no gap between the coil and the core. Therefore, the heat dissipation of the stator can be improved. Moreover, the insulation between adjacent coils can be reliably performed by resin-molding the coil side end face. In addition, by using resin, even if there are irregularities in the coil end face or core end face, such as when there is a dimensional variation in the coil or core, the resin spreads uniformly along the shape of the coil end face or core end face. And dimensional variations of the core can be absorbed.

  In addition to the first feature of the present invention, the stator of the present invention has a second feature that the coil is closely attached in the coil axial direction.

  According to the second feature of the present invention, in addition to the function and effect of the first feature of the present invention, the coil is configured to be in close contact with the coil axis direction. There are no gaps. Therefore, the heat dissipation of the stator can be improved.

  In addition to the first or second feature of the present invention, the stator of the present invention has a third feature that the coil terminal is exposed as a coil without exposing the coil to resin molding. .

  According to the third feature of the present invention, in addition to the operational effects of the first or second feature of the present invention, the coil terminal is provided as a coil exposed portion with the coil exposed without resin molding. Because the structure does not require insulation on the part of the coil that does not come into contact with the core, the amount of resin used can be reduced by making the coil exposed part a coil terminal that does not make contact with the core and does not require resin molding. Thus, the stator can be made in consideration of cost, and the power supply to the coil can be effectively performed.

  In addition to the features described in any one of the first to third aspects of the present invention, the stator of the present invention is characterized in that a bus bar fitting groove is formed on the resin surface applied to the end face of the coil end. 4 features.

  According to the fourth aspect of the present invention, in addition to the function and effect of any one of the first to third aspects, the bus bar fitting groove is formed on the resin surface applied to the coil end end surface. Therefore, there is no need to separately provide parts for connecting the bus bars. Therefore, the manufacturing cost can be reduced, and the connection between the stator and the bus bar can be easily and reliably performed.

  In addition to the feature described in any one of the first to fourth aspects of the present invention, the stator of the present invention has a fifth feature that the core is a split stator core.

  According to the fifth feature of the present invention, in addition to the operational effect of the feature according to any one of the first to fourth features of the present invention, the core is configured as a split stator core. By dividing the core constituting the stator, the manufacturing process can be subdivided, and the divided stator itself can be manufactured in one process of resin-molding the coil and the core. Therefore, it can be set as a stator with much higher manufacturing efficiency.

  In addition to the feature described in any one of the first to fifth aspects of the present invention, the stator of the present invention has a sixth feature that the core is made of an electromagnetic steel plate.

  According to the sixth feature of the present invention, in addition to the function and effect of any one of the first to fifth features of the present invention, the core is composed of a magnetic steel sheet. The electromagnetic steel sheet can be easily manufactured by punching the steel sheet, and the manufacturing efficiency of the stator can be improved.

  The stator of the present invention has a seventh feature that, in addition to the characteristics described in any one of the first to fifth aspects of the present invention, the core is composed of a dust core.

  According to the seventh feature of the present invention, in addition to the function and effect of any one of the first to fifth features of the present invention, the core is composed of a dust core. By using a dust core having a high degree of freedom in shape and high thermal conductivity, the manufacturing efficiency and heat dissipation of the stator can be improved. Further, since the dust core can be easily broken by applying an impact load, the stator can be made in consideration of recyclable cost.

  In the stator manufacturing method of the present invention, the coil and the core are integrally formed by injecting resin into at least the coil and the core and the coil side end face in a state where the coil and the core are fitted in the mold. This is the eighth feature.

  According to the eighth aspect of the present invention, the coil and the core are integrated by injecting resin at least between the coil and the core and the coil side end face in a state where the coil and the core are fitted in the mold. Since it is configured to be molded, the stator itself can be manufactured by integrally molding the coil and the core with resin in the mold. Therefore, it can be set as the manufacturing method of a stator with high manufacturing efficiency. Further, by injecting a resin between the coil and the core, the coil and the core can be insulated, and the space between the coil and the core can be filled with the resin. Therefore, there is no gap between the coil and the core. Therefore, a stator with good heat dissipation can be obtained. Further, by injecting resin into the coil side end face, insulation between adjacent coils can be reliably performed. In addition, by using resin, even if there are irregularities in the coil end face or core end face, such as when there is a dimensional variation in the coil or core, the resin spreads uniformly along the shape of the coil end face or core end face. And dimensional variations of the core can be absorbed.

  Further, in the stator manufacturing method of the present invention, in addition to the eighth feature of the present invention, the integral molding of the coil and the core includes a core arranging step of arranging at least the core in a mold, and the coil is arranged as described above. It is performed by a coil placement step of placing the mold so that a gap is left between the core and a resin injection step of injecting resin between the coil and the core placed in the die and the coil side end face. Is the ninth feature.

  According to the ninth feature of the present invention, in addition to the function and effect of the eighth feature of the present invention, the integral molding of the coil and the core includes a core placement step of placing at least the core in the mold, A coil placement step of placing the metal in the mold so that a gap is left between the core and the resin, and a resin injection step of injecting a resin between the coil and the core placed in the mold and the coil side end face Therefore, the core can be surely arranged on the mold by the core arranging step. Moreover, a coil can be arrange | positioned to a metal mold | die in the state which opened the clearance gap between the coil and the core reliably by the coil arrangement | positioning process. Further, the resin can be reliably injected between the coil and the core disposed in the mold and the coil side end face by the resin injection step.

  In addition to the eighth or ninth feature of the present invention, the stator manufacturing method according to the present invention further includes a coil contact step in which the coil and the core are integrally formed in a state in which the coil is in close contact with the coil axis direction. Use is the tenth feature.

  According to the tenth feature of the present invention, in addition to the operational effects of the eighth or ninth feature of the present invention, the coil and the core are integrally molded, and the coil is in close contact with the coil axis direction. Since there is a configuration using the coil contact process, there is no gap between the conducting wires constituting the coil. Therefore, a stator with good heat dissipation can be obtained.

  Further, in the stator manufacturing method of the present invention, in addition to the ninth or the tenth feature of the present invention, the coil fitting step uses a coil positioning means for positioning the coil positioning position with respect to the mold. The eleventh feature is to perform the above.

  According to the eleventh feature of the present invention, in addition to the function and effect of the ninth or tenth feature of the present invention, the coil fitting step includes the coil positioning means for positioning the coil arrangement position with respect to the mold. Since the coil is arranged to be used, the coil positioning means can be used to reliably position the coil with respect to the mold so that the coil can be arranged. can do.

  In addition to the eleventh feature of the present invention, the stator manufacturing method of the present invention has a twelfth feature in that the coil positioning by the coil positioning means is performed by restricting the four corners of the coil.

  According to the twelfth feature of the present invention, in addition to the function and effect of the eleventh feature of the present invention, the coil positioning by the coil positioning means is performed by restricting the four corners of the coil. By restricting the four corners of the coil, the arrangement position of the coil with respect to the mold can be more reliably positioned. Therefore, it can be set as the manufacturing method of a stator with high manufacturing efficiency.

  According to the stator manufacturing method of the present invention, in addition to the eleventh or twelfth feature of the present invention, the coil positioning means includes a mechanism for urging the arrangement position of the coil in the mold. It has the characteristics of

  According to the thirteenth feature of the present invention, in addition to the function and effect of the eleventh or twelfth feature of the present invention, the coil positioning means includes a mechanism for biasing the arrangement position of the coil in the mold. Since it is provided as a configuration, even when there is a dimensional variation in the coil, the arrangement position of the coil with respect to the mold can be flexibly changed and arranged at an appropriate position.

  In addition to the features described in any one of the ninth to thirteenth aspects of the present invention, the method for manufacturing a stator of the present invention includes a core positioning means for positioning the core layout position with respect to the mold. The fourteenth feature is that the cores are arranged using.

  According to the fourteenth feature of the present invention, in addition to the function and effect of any one of the ninth to thirteenth features of the present invention, the core placement step determines the placement position of the core relative to the mold. Since the core is positioned using the core positioning means for positioning, the core positioning position can be used to reliably position the core with respect to the mold and to place the core. A good stator manufacturing method can be obtained.

  In addition to the fourteenth feature of the present invention, the stator positioning method of the present invention has a fifteenth feature that the core positioning means includes a mechanism for spring-biasing the arrangement position of the core in the mold. Yes.

  According to the fifteenth feature of the present invention, in addition to the function and effect of the fourteenth feature of the present invention, the core positioning means includes a mechanism for biasing the arrangement position of the core in the mold. For this reason, even when there is a dimensional variation in the core, the arrangement position of the core with respect to the mold can be flexibly changed and arranged at an appropriate position.

  According to the stator and the manufacturing method of the stator of the present invention, the coil and the core are integrally formed of resin, so that there is no gap between the coil and the core and the dimensional variation of the coil and the core is absorbed. Thus, the heat dissipation can be improved, and the stator and the method for manufacturing the stator can be manufactured with high manufacturing efficiency.

  With reference to the following drawings, a stator and a method for manufacturing a stator according to an embodiment of the present invention will be described for understanding of the present invention. However, the following description is an embodiment of the present invention, and does not limit the contents described in the claims.

  FIG. 1 is an overall perspective view of a stator and a bus bar according to an embodiment of the present invention. FIG. 2 is a partially enlarged view of FIG. 3A and 3B are perspective views of the coil according to the embodiment of the present invention, in which FIG. 3A shows a normal state, and FIG. FIG. 4 is a horizontal sectional view of FIG. FIG. 5 is an exploded perspective view showing a stator manufacturing method according to an embodiment of the present invention, and shows a state in which a coil and a core are arranged in a mold. 6A and 6B are exploded perspective views showing a stator manufacturing method according to an embodiment of the present invention. FIG. 6A shows a state in which a coil and a coil mold are fitted together, and FIG. 6B shows a state in which the coil mold and a lower mold are fitted together. The combined state is shown. FIG. 7 is an exploded perspective view showing a stator manufacturing method according to an embodiment of the present invention. FIG. 7A shows a state in which the coil is in close contact with the coil in the axial direction, and FIG. Indicates the state that has been performed. FIG. 8 is a plan view in a state where the coil mold and the lower mold are fitted together. FIG. 9 is a vertical cross-sectional view in the longitudinal direction of the coil in FIG.

  First, a stator 1 according to an embodiment of the present invention will be described with reference to FIGS. The stator 1 is a divided stator of a motor, and is composed of a plurality of divided stators 100 and fastening rings 200 that are in contact with each other and arranged in a ring shape. The stator 1 is connected to a bus bar 300 for supplying power.

  The divided stator 100 is a divided stator that constitutes the stator 1, and includes a coil 10, a core 20, and a resin 30.

The coil 10 is a rectangular wire edgewise winding coil. Although not shown in detail in FIGS. 1 and 2, the flat wire constituting the coil 10 is in close contact with the coil axis direction. With such a configuration, there is no gap between adjacent rectangular wires. Therefore, the heat conduction between the rectangular wires can be improved. Therefore, the heat dissipation of the stator 1 can be improved.
That is, as shown in FIG. 3 (a), the coil 10 has a gap 10a between adjacent rectangular wires. As shown in FIG. 3 (b), the rectangular wire is brought into close contact with the coil axis direction. Adjacent rectangular wires can be brought into close contact with each other without a gap.

  The rectangular wire constituting the coil 10 may be any wire as long as it is normally used as a wire, such as copper, aluminum, silver, gold, and alloys thereof. Further, the flat wire may be either an assembly line composed of a plurality of strands or a strand composed of a single strand. Further, it is not necessarily a flat wire, and the shape, material, conductive diameter and the like can be appropriately changed as long as it is normally used as a wire constituting a coil such as a round wire, a hexagonal wire, and a rectangular wire.

  The core 20 is a split stator core. As shown in FIGS. 2 and 4, the core 20 is composed of a yoke portion 21 and a tooth portion 22, as in a normal stator core of a split stator, and has an outer shape that is substantially T-shaped. Further, the teeth portion 22 is arranged in a state where the stator 1 is formed, and is opposed to a permanent magnet disposed on the outer peripheral surface of the rotor not shown in detail in FIG. As shown in FIGS. 1 and 2, the core 20 is formed by laminating a plurality of thin electromagnetic steel plates. Thus, by using an electromagnetic steel sheet as the core 20, the electromagnetic steel sheet can be easily manufactured by punching the steel sheet, and the manufacturing efficiency of the stator 1 can be improved.

The core 20 does not necessarily need to be an electromagnetic steel plate, and may be any one as long as it can be used as a motor core. For example, a dust core can be used. By using a dust core having a high degree of freedom in shape and high thermal conductivity, the manufacturing efficiency and heat dissipation of the stator 1 can be improved. Further, since the dust core can be easily broken by applying an impact load, the stator 1 can be made in consideration of the recyclable cost.
The core 20 is not necessarily a motor core, and may be a core of various generators such as a transformer and a reactor.

  Here, as shown in FIG. 2, the inner periphery of the coil 10 has a gap L between the inner peripheral surface of the coil 10 and the outer peripheral surface of the tooth portion 22 when the coil 10 and the core 20 are fitted together. In addition, it is necessary to be larger than the outer periphery of the tooth portion 22. Moreover, it is desirable that the thickness of the gap L be a thickness sufficient to satisfy the insulation against the line voltage according to the applied voltage or the connection method by being molded with the resin 30. For example, it can be set to 0.3 to 0.5 mm.

  As shown in FIGS. 2 and 4, the total axial length of the coil 10 closely attached in the coil axial direction is a gap between the coil 10 and the yoke portion 21 when the coil 10 and the core 20 are fitted together. It is desirable that M is empty and that the rotor-side end surface 12 of the coil 10 and the rotor-side end surface 22a of the tooth portion 22 be flush with each other. Further, the thickness of the gap M is desirably set to a thickness sufficient to satisfy the insulation with respect to the line voltage according to the applied voltage or the connection method by being molded with the resin 30. For example, it can be set to 0.3 to 0.5 mm.

The resin 30 is for molding and integrating the coil 10 and the core 20.
As shown in FIGS. 2 and 4, the coil end end surface 13, the coil side end surface 14, and the gaps L and M are completely molded with a resin 30 except for the coil terminal 11 and the rotor side end surface 12 in the coil 10. Yes. By adopting such a configuration, there is no gap between the coil surface excluding the coil terminal 11 and the rotor side end face 12 and the resin 30. Therefore, the heat generated in the coil 10 can be quickly conducted to the outside through the resin 30 that is in close contact with the coil 10 without passing through an air layer, and can be dissipated. Therefore, the heat dissipation of the stator 1 can be improved.

  Further, since the coil side end face 14 is resin-molded, insulation between adjacent coils can be reliably performed. Further, by using the coil terminal 11 and the rotor side end surface 12 that do not come into contact with the core 20 and do not need to be resin-molded as the coil exposed portion, the amount of resin used can be suppressed, and a cost-conscious stator 1 can be used. Of course, the coil 10 molded with the resin 30 is protected from external damage.

Further, as shown in FIG. 4, the gaps L and M can be completely filled with the resin 30. Therefore, the coil 10 and the core 20 can be brought into close contact via the resin 30. Therefore, the coil 10 and the core 20 can be reliably insulated. Further, the heat generated in the coil 10 easily conducts heat in the coil 10 that is in close contact in the axial direction, and quickly conducts heat from the coil 10 to the core 20 through the resin 30 that is in close contact therewith. Can be done. In addition, the coil 10 and the core 20 are integrated with the resin 30, so that rattling of the coil 10 can be surely prevented, and the subsequent motor formation burden can be reduced, thereby improving work efficiency. Can do.
Even when the coil 10 or the core 20 has a dimensional variation, even when the coil end face or the core end face is uneven, the resin 30 spreads uniformly along the shape of the coil end face or the core end face. It is possible to absorb the dimensional variation of the end face. Therefore, the stator 1 having good heat dissipation can be obtained.

  2 and 4, when the gaps L and N are molded with the resin 30, the rotor side end surface of the split stator 100 including the rotor side end surface 22a of the teeth portion 22 and the rotor side end surface 12 of the coil 10. Is configured to be flush with each other. With such a configuration, an air layer is not formed on the rotor-side end surface of the split stator 100. Therefore, it can be set as the stator 1 excellent in heat dissipation.

As shown in FIGS. 1 and 2, a bus bar fitting for connecting a bus bar 300 to be described later to the resin surface 31 provided on the coil end end surface 13 on the coil terminal 11 side among the two coil end end surfaces 13. A combination groove 32 is formed. With such a configuration, it is not necessary to separately provide components for connecting the bus bar 300. Therefore, the manufacturing cost can be suppressed. Further, the stator 1 and the bus bar 300 can be easily and reliably connected.
The shape and number of the bus bar fitting grooves 32 are not limited to those of the present embodiment, and need not necessarily be grooves, and can be easily and reliably connected to the bus bar 300 by being provided on the resin surface 31. As long as it can be changed, it can be changed as appropriate. In addition, it is not always necessary to provide the resin surface 31, and it is possible to separately provide components for connecting the bus bar 300, but it is desirable to provide the resin surface 31 in consideration of manufacturing cost and connectivity.

The resin 30 may be any resin as long as it is normally used as a mold resin, such as a thermosetting resin such as an epoxy resin or a thermoplastic resin.
In the present embodiment, the coil end end face 13 is molded with the resin 30 and the rotor side end face 12 is not molded with the resin 30. However, these portions are portions that do not come into contact with the core 20 and the adjacent coil 10, and are not necessarily molded with the resin 30. Therefore, it is not always necessary to adopt the configuration as in the present embodiment, and either or both may be molded with the resin 30 or may not be molded. In addition, when the rotor side end surface 12 is molded with the resin 30, it is desirable to mold so that the rotor side end surface of the divided stator 100 is flush with the heat dissipation of the stator 1.

  As shown in FIG. 1, the fastening ring 200 is a ring for integrating a plurality of divided stators 100 arranged in a ring shape in contact with each other by shrinkage. The fastening ring 200 may have any shape, material, etc. as long as it is normally used as a ring used for shrinkage.

The bus bar 300 is a unit for supplying power to the stator 1. As shown in FIG. 2, the bus bar 300 is provided with a convex portion 300 a having the same shape as the bus bar fitting groove 32 provided on the resin surface 31. With such a configuration, the bus bar 300 can be easily and reliably connected to the stator 1 only by fitting the convex portion 300 a into the bus bar fitting groove 32. Although not shown, the bus bar 300 is provided with power supply wires and input / output terminals.
The shape, size, and the like of the bus bar 300 are not limited to those shown in the present embodiment, and may be any as long as they are normally used for supplying power to the stator 1.

  Next, a method for manufacturing the stator 1 according to the embodiment of the present invention will be described with reference to FIGS. The stator 1 according to the embodiment of the present invention is a stator of a motor. In this stator 1, a split stator 100 composed of a coil 10, a core 20, and a resin 30 is integrally formed in a mold 400, and a plurality of split stators 100 are in contact with each other in a ring shape. It is manufactured by arranging and integrating with the fastening ring 200.

First, the coil 10 and the core 20 are arranged in a simplified mold 400.
As shown in FIG. 5, the mold 400 is composed of a lower mold 410, a coil mold 420, a coil contact mold 430, and an upper mold 440. The coil mold 420 is further composed of two members. The lower coil 421 and the upper coil 422 are configured.
Further, as shown in FIG. 5, the lower mold 410, the coil mold 420, and the upper mold 440 are fitted with respective molds, and finally the lower mold 410, the coil mold 420, and the upper mold 440 are combined. The fitting convex part and fitting concave part for integrating all are provided.

Next, a core arrangement process will be described with reference to FIGS. The core placement step is a step of placing the core 20 on the lower mold 410.
As shown in FIGS. 5 and 6, the lower die 410 is provided with a core fitting recess 411 for fitting the core 20 and a support piece 412 for supporting the coil 10.

First, a core positioning means (not shown) is operated in a state where the core 20 is arranged in the mold 400, and the arrangement position with respect to the lower mold 410 of the core 20 is determined. As the core positioning means, for example, a gripping tool incorporating a sensor capable of capturing an appropriate arrangement position with respect to the lower mold 410 of the core 20 can be used. By setting it as such a structure, the arrangement position with respect to the lower mold | type 410 of the core 20 can be positioned reliably. Therefore, it can be set as the manufacturing method of the stator 1 with high manufacturing efficiency.
Of course, the core positioning means does not necessarily have to be a gripper with a built-in sensor, and may be any one that can position the arrangement position of the core 20 with respect to the lower mold 410.

The core positioning unit includes a spring biasing mechanism (not shown). By adopting such a configuration, even when there is a dimensional variation in the core 20, the arrangement position of the core 20 with respect to the lower mold 410 can be flexibly changed and arranged at an appropriate position.
Then, as shown in FIG. 6A, the core 20 is disposed on the lower mold 410 by fitting the core 20 and the core fitting recess 411 together.

Next, the coil arrangement process will be described with reference to FIGS. 1, 2, and 5 to 9. The coil placement step is a step of placing the coil 10 on the lower die 410 using the coil die 420 so that a gap is left between the core 20 placed on the lower die 410. By this step, the coil 10 and the core 20 are fitted together.
As shown in FIGS. 5 and 6, the coil lower mold 421 is provided with a coil terminal fitting groove 421 a for fitting the coil terminal 11 a and gripping convex portions 421 b for gripping the four corners of the coil 10.
Further, as shown in FIGS. 5 and 6, the coil upper mold 422 is provided with a coil terminal fitting groove 422 a for fitting the coil terminal 11 b and grip convex portions 422 b for gripping the four corners of the coil 10.

First, in a state where the coil 10 is placed in the mold 400, the coil terminal 11a and the coil lower mold 421 including the coil terminal fitting groove 421a are fitted in the direction of the black arrow shown in FIG. In this state, the other lower coil mold 421 is integrated in the direction of the black arrow shown in FIG.
FIG. 6A shows a state where the coil 10 and the coil lower mold 421 are fitted together.
And the coil terminal 11b and the coil upper mold | type 422 provided with the coil terminal fitting groove part 422a are fitted in the black arrow direction shown in FIG. In this state, the other upper coil mold 422 is integrated in the direction of the black arrow shown in FIG.
FIG. 6A shows a state where the coil 10 and the coil upper mold 422 are fitted together.

In this way, by providing the grip convex portions 421b and 422b on the lower coil mold 421 and the upper coil mold 422, the coil 10 and the coil mold 420 are fitted together as shown in FIGS. In the state, the four corners of the coil 10 can be reliably gripped by the gripping convex portions 421b and 422b. Further, by adopting a configuration in which the four corners are gripped, the coil 10 can be reliably gripped and moved without causing a shake in the coil 10 even with a relatively small force. Further, the coil 10 can be prevented from being damaged by not gripping the coil 10 with a strong force.
Although not shown, the gripping convex portions 421b and 422b are each provided with a telescopic mechanism, whereby the gripping force on the coil 10 is adjusted.

  Moreover, by making it a convex part, as shown to FIG. 6, FIG. 7, the clearance gap N can be vacated between the coil 10 and the coil type | mold 420. FIG. Therefore, as shown in FIG. 7, when all of the lower mold 410, the coil mold 420, and the upper mold 440 are integrated, this gap N becomes a resin injection space, and the resin 30 is injected into the gap N. A portion of the coil 10 that contacts the gap N can be molded with the resin 30.

  Further, as shown in FIGS. 5 to 7, a bus bar fitting groove forming convex portion 422 c is provided on the coil upper die 422. With such a configuration, a gap N is provided between the coil 10 and the coil upper mold 422, and the gap N becomes a resin injection space. The resin surface 31 applied to the coil end end face 13 The bus bar fitting groove 32 can be formed. Therefore, there is no need to separately provide components for connecting the bus bar 300. Therefore, the manufacturing cost can be reduced, and the stator 1 and the bus bar 300 can be easily and reliably connected.

  Further, the bus bar fitting groove forming convex part 422c is provided at a position facing the coil end end face 13 on the coil terminal 11b side, as shown in FIGS. With such a configuration, as shown in FIGS. 1 and 2, the coil terminal 11 and the bus bar fitting groove 32 can be provided on the same surface in the split stator 100. Therefore, the stator 1 and the bus bar 300 can be connected easily and reliably.

Then, a coil positioning means (not shown) is operated in a state where the coil 10 is gripped by the gripping convex portions 421b and 422b, and the arrangement position of the coil 10 with respect to the lower mold 410 is determined. More specifically, as shown in FIG. 8, the arrangement position of the coil 10 with respect to the lower mold 410 is positioned so that a gap L is provided between the inner periphery of the coil 10 and the outer periphery of the core 20.
As the coil positioning means, for example, a sensor capable of capturing an appropriate arrangement position with respect to the lower mold 410 of the coil 10 can be incorporated in the gripping convex portions 421b and 422b. By setting it as such a structure, the arrangement position with respect to the lower mold | type 410 of the coil 10 can be reliably positioned in the state which controlled the four corners of the coil 10. FIG. Therefore, it can be set as the manufacturing method of the stator 1 with high manufacturing efficiency.

It is desirable that the gap L has a thickness sufficient to satisfy the insulation against the line voltage according to the applied voltage or the connection method by being molded with the resin 30. For example, it can be set to 0.3 to 0.5 mm.
Of course, the coil positioning means is not necessarily limited to the sensor built in the gripping convex portions 421b and 422b, and the gap L is opened with a predetermined thickness between the inner periphery of the coil 10 and the outer periphery of the core 20. Any arrangement can be used as long as the arrangement position of the coil 10 with respect to the lower mold 410 can be determined.

  Further, the grip convex portions 421b and 422b are provided with a spring urging mechanism (not shown). With such a configuration, even when the coil 10 has dimensional variations, the arrangement position of the coil 10 with respect to the lower mold 410 can be flexibly changed and arranged at an appropriate position.

  Then, the coil 10 is placed on the lower mold 410 by fitting the coil mold 420 and the lower mold 410 together. At this time, as shown in FIGS. 6, 7, and 9, when the coil lower mold 421 and the lower mold 410 are fitted together, the coil 10 is placed on a support piece 412 provided on the lower mold 410. Become. With such a configuration, as shown in FIG. 9, a gap M can be formed between the lower end surface of the coil 10 and the upper end surface of the lower mold 410. Therefore, the gap M becomes a resin injection space, and the resin 30 is injected, so that the insulation between the coil 10 and the core 20 is ensured and the coil 10 and the core 20 are reliably integrated as shown in FIG. Can be made. In addition, as shown in FIG. 7, the close contact of the coil 10 in the coil close contact process described later is to press the coil 10 downward from above, and the support piece 412 can be used as a base of the coil 10 at the time of pressing. The coil 10 can be surely pressed downward.

Next, the coil contact process will be described with reference to FIGS. The coil contact process is a process in which the coil 10 is contacted in the axial direction with the coil contact mold 430.
The coil contact mold 430 is provided with a pin jig 431 as shown in FIGS. Further, as shown in FIGS. 6, 7, and 9, the upper die 440 is provided with a pin jig insertion hole 441 through which the pin jig 431 is inserted.

  First, as shown in FIG. 6A, the lower coil mold 421 is lowered in the direction of the black arrow. Then, as shown in FIG. 6B, the coil contact mold 430 and the upper mold 440 are lowered in the black arrow direction in a state where the coil lower mold 421 and the lower mold 410 are fitted together. Here, as shown in FIG. 6, the pin jig 431 can be advanced from the upper part to the lower part of the upper mold 440 through the pin jig insertion hole 441 so as to be able to advance and retract. Then, as shown in FIG. 7, the pin jig 431 is used to press and compress the coil 10 in the axial direction and hold the adjacent flat portions of the coil 10 so as to be in close contact with each other. In FIG. 6 and FIG. 7, each pin jig 431 pushes the coil 10 vertically downward from above. More specifically, the lower end surfaces of the four pin jigs 431 are brought into contact with the respective central portions of the four corners of the flat portion on the uppermost surface of the coil 10 so as to apply a pressing force.

  Further, the pin jig 431 can be provided with an elastic force larger than the elastic repulsion force of the coil 10 in the pressing direction. As a result, the coil 10 can be held in a compressed state with a uniform pressing force on the coil 10. That is, it is possible to prevent the pressing force biased on a part of the coil 10 from being improperly applied.

  Although not shown, the pin jig 431 is provided with driving means for moving the pin jig 431 forward or backward. Further, in the mold using the mold 400, the driving means is added with a control means so that the pin jig 431 can be advanced and retracted at a fixed timing during the series of molding operations. . Conventionally known technical means can be used for these driving means and control means.

The number of pin jigs 431, the pressing position of the coil 10, the thickness, etc. can be changed as appropriate.
In the present embodiment, the pin jig 431 is used as means for bringing the coil 10 into close contact with the coil axis direction. However, the present invention is not limited to this, and the coil 10 is brought into close contact with the coil axis direction within the mold 400. Anything can be used as long as it can be applied.

  In addition, a configuration in which the coil 10 is closely attached in the axial direction in advance before the coil 10 is disposed in the mold 400 without providing the coil contact process may be employed. As such, for example, a method in which a thin heat-resistant tape is wound or fixed with a clip with the coil 10 in close contact in the axial direction, or a coil having a self-fusing insulating coating is used as the coil 10 after coiling. A method of fixing the coil 10 by applying hot air or energizing it can be used.

Then, when the coil 10 is brought into close contact with the pin jig 431 in the axial direction, the lower coil mold 421 and the upper coil mold 422 are fitted and integrated as shown in FIG.
Thus, a space | gap is not produced between the rectangular wires which comprise the coil 10 by closely_contact | adhering the coil 10 to a coil axial direction. Therefore, the heat dissipation of the stator 1 can be improved.

Next, the resin injection process will be described with reference to FIGS. The resin injection process is a process in which the coil 10 and the core 20 are molded and integrated by injecting the resin 30 into the mold 400.
As shown in FIG. 7, the upper die 440 is lowered in the direction of the black arrow in a state where the coil 10 is in close contact with the pin jig 431 in the axial direction and the coil lower die 421 and the coil upper die 422 are integrated. . Then, the upper mold 440 and the coil upper mold 422 are fitted together. Thus, the lower die 410, the coil die 420, and the upper die 440 are integrated. Then, the resin 30 is injected into the mold 400 at a predetermined temperature through an injection passage (not shown).

Here, as shown in FIG. 9, the coil 10 and the upper mold 440 are in close contact with each other. By setting it as such a structure, the rotor side end surface 12 can be made into the coil exposure part which is not molded by the resin 30. FIG.
Of course, such a configuration is not necessarily required, and a configuration may be adopted in which a gap is formed between the coil 10 and the upper mold 440 and molding is performed with the resin 30.

  Although not shown in detail, after the coil mold 420 and the lower mold 410 are fitted together, the coil gripping convex portions 421b and 422b contract to the gripping convex portion contraction line 422d shown in FIG. As a result, portions of the coil 10 that are gripped by the coil gripping convex portions 421 b and 422 b can be molded with the resin 30. Also, as shown in FIG. 8, the inner periphery of the coil mold 420 can be a plane. Therefore, the outer peripheral surface of the resin 30 for molding the gap N can be a flat surface.

  The resin injection step in this embodiment is performed by so-called injection molding in which the resin 30 is press-fitted into the mold 400. Of course, it is not always necessary to perform injection molding, and any material may be used as long as the coil 10 and the core 20 can be integrally molded using the resin 30 such as transfer molding or potting molding.

The divided stator 100 is formed through the above steps.
And the stator 1 is shape | molded by arrange | positioning the some split stator 100 in the state which contact | abutted by the side surfaces, and shrinking | fitting using the fastening ring 200. FIG.

  In the present embodiment, the stator 1 is constituted by a plurality of divided stators 100, but is not necessarily constituted by divided stators. The lower mold 410, the coil mold 420, and the coil that constitute the mold 400 are not necessarily required. The shape, size, number, fitting order, manufacturing process, and the like of the contact mold 430 and the upper mold 440 need not be limited to those of the present embodiment, and may be appropriately selected as long as the stator 1 can be manufactured finally. It can be changed.

  INDUSTRIAL APPLICABILITY The present invention can be used as various stators such as motors, transformers, and reactors that require various stators, and generators.

1 is an overall perspective view of a stator and a bus bar according to an embodiment of the present invention. It is the elements on larger scale of FIG. It is a perspective view of the coil which concerns on embodiment of this invention, (a) shows a normal state, (b) shows the state which closely_contact | adhered. FIG. 3 is a horizontal sectional view of FIG. 2. It is a disassembled perspective view which shows the manufacturing method of the stator which concerns on embodiment of this invention, and shows the state which has arrange | positioned the coil and the core in a metal mold | die. It is a disassembled perspective view which shows the manufacturing method of the stator which concerns on embodiment of this invention, (a) shows the state which fitted the coil and the coil type | mold, (b) the state which fitted the coil type | mold and the lower mold | type Indicates. It is a disassembled perspective view which shows the manufacturing method of the stator which concerns on embodiment of this invention, (a) shows the state which closely_contact | adhered the coil to the axial direction with the coil contact | adherence type, (b) is the state with which the metal mold | die was integrated. Indicates. It is a top view in the state where a coil type and a lower type were fitted together. It is the vertical sectional view of the longitudinal direction of the coil in FIG.7 (b).

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Stator 10 Coil 10a Crevice 11 Coil terminal 11a Coil terminal 11b Coil terminal 12 Rotor side end surface 13 Coil end end surface 14 Coil side end surface 20 Core 21 York portion 22 Teeth portion 22a Rotor side end surface 30 Resin 31 Resin surface 32 Bus bar fitting groove 100 Split stator 200 Fastening ring 300 Bus bar 300a Protruding portion 400 Mold 410 Lower die 411 Core fitting concave portion 412 Support piece 420 Coil type 421 Coil lower die 421a Coil terminal fitting groove portion 421b Holding convex portion 422 Coil upper die 422a Coil terminal fitting Groove 422b Grip convex 422c Bus bar fitting groove forming convex 422d Grip convex shrinkage line 430 Coil contact type 431 Pin jig 440 Upper mold 441 Pin jig insertion hole L Gap M Gap N Gap

Claims (15)

  A stator comprising a coil and a core fitted together, wherein the coil and the core are integrally formed by resin molding at least between the coil and the core and the coil side end face.   The stator according to claim 1, wherein the coil is in close contact with the coil axis direction.   3. The stator according to claim 1, wherein the coil terminal is a coil exposed portion where the coil is exposed without being resin-molded. 4.   The stator according to any one of claims 1 to 3, wherein a bus bar fitting groove is formed on a resin surface applied to the end face of the coil end.   The stator according to any one of claims 1 to 4, wherein the core is a split stator core.   The stator according to any one of claims 1 to 5, wherein the core is made of an electromagnetic steel plate.   The stator according to any one of claims 1 to 5, wherein the core is formed of a powder magnetic core.   A stator manufacturing method, wherein a coil and a core are integrally formed by injecting resin at least between the coil and the core and the coil side end face in a state where the coil and the core are fitted in a mold.   The integral molding of the coil and the core includes at least a core arranging step of arranging the core in the die, a coil arranging step of arranging the coil in the die so that a gap is provided between the arranged core, and the die The method for manufacturing a stator according to claim 8, wherein the method is performed by a resin injection step of injecting resin between a coil and a core disposed inside and a coil side end face.   10. The method for manufacturing a stator according to claim 8, wherein a coil contact process for bringing the coil into close contact with the coil axis direction is used for integral molding of the coil and the core. 11.   The method for manufacturing a stator according to claim 9 or 10, wherein the coil placement step performs coil placement by using a coil positioning means for positioning a coil placement position with respect to a mold.   The stator manufacturing method according to claim 11, wherein positioning of the coil by the coil positioning means is performed by regulating four corners of the coil.   The method for manufacturing a stator according to claim 11 or 12, wherein the coil positioning means includes a mechanism for urging the arrangement position of the coil in the mold.   The method for manufacturing a stator according to any one of claims 9 to 13, wherein in the core arranging step, the core is arranged by using a core positioning means for positioning a core arranging position with respect to the mold.   The method of manufacturing a stator according to claim 14, wherein the core positioning means includes a mechanism that biases the arrangement position of the core in the mold.

Images