JP2019054622A - Stator, motor, and manufacturing method of stator - Google Patents

Abstract

To provide a stator capable of easily bending a plurality of core pieces aligned in a straight line, and suppressing variation in a distance from a central axis of each core piece.SOLUTION: A stator includes a stator core and an insulator covering the stator core. The stator core is composed of a plurality of core pieces 401 to 406, the insulator is composed of a plurality of insulator pieces, a first insulator piece and a second insulator piece which are respectively positioned adjacent are connected by a connecting portion, the connecting portion includes a first support portion which extends between a first end connected to the first insulator piece and a second end positioned closer to the second insulator piece side than the first end and radially outward and a second support portion which extends between a third end connected to the second insulator piece and a fourth end positioned closer to the first insulator piece side than the third end and radially outward, and the second end and the fourth end are faced each other in a circumferential direction.SELECTED DRAWING: Figure 3

Description

  The present invention relates to a stator, a motor, and a method for manufacturing a stator.

  2. Description of the Related Art Conventionally, a method for forming an annular stator core by bending a so-called straight core in which a plurality of divided core portions are arranged in a straight line is known when manufacturing a stator used in a motor. About the manufacturing method of the stator using a straight core, it describes in Unexamined-Japanese-Patent No. 2011-019360, for example.

In the stator manufacturing method described in Japanese Patent Application Laid-Open No. 2011-019360, a split insulator is attached to each of a plurality of split cores, and the split insulators are connected by a connecting means to form a connected body. Thereafter, the connecting body is formed into a linear shape, and a winding is wound around each divided core. After winding, the connecting body is deformed from a linear shape to an annular shape.
JP 2011-019360 A

  In the method described in Japanese Patent Application Laid-Open No. 2011-019360, when winding a winding around each divided core, the winding machine needs to be moved. In this case, since the divided insulators connected by the connecting means need to be kept in a straight line shape, a connecting force by the connecting means is required to some extent. On the other hand, if the coupling force is too strong, it is difficult to deform the coupled body from a linear shape to an annular shape.

  Accordingly, an object of the present invention is to provide a technique that can easily bend a plurality of core pieces arranged in a straight line, and that can suppress variation in the distance from the central axis of each core piece in a stator core after manufacture. .

  A first invention of the present application is a stator used in a motor, a stator core that is a magnetic body having a plurality of teeth extending in the radial direction, surrounding a central axis extending vertically, and a resin insulator covering the stator core; The stator core is configured by a plurality of core pieces arranged in a circumferential direction, and the insulator is configured by a plurality of insulator pieces covering each of the plurality of core pieces, and is adjacent to each other among the plurality of insulator pieces. A 1st insulator piece and a 2nd insulator piece are connected by the connection part, and the said connection part is a said 1st end part connected to a said 1st insulator piece, and a said 2nd insulator rather than a said 1st end part. A second end located on the piece side and radially outside, and the first end A first support portion extending between the second end portion, a third end portion connected to the second insulator piece, the first insulator piece side and a radially outer side than the third end portion; And a second support portion extending between the third end portion and the fourth end portion, wherein the second end portion and the fourth end portion are circumferential. Facing each other.

  2nd invention of this application is a manufacturing method of the stator used for a motor, Comprising: a) The process of forming multiple core pieces which have a core back and the teeth which protruded from the said core back, b) For every said core piece And c) a step of connecting adjacent first and second insulator pieces at a connecting portion among the plurality of core pieces arranged in a straight line, and d) A step of winding a conductive wire around the teeth via the insulator piece, and e) a step of bending the plurality of core pieces in an annular shape, wherein the connecting portion is connected to the first insulator piece. A second end located on the second insulator piece side and radially outside the first end, and the first end and the front A first support portion extending between the second end portion, a third end portion connected to the second insulator piece, and on the first insulator piece side and radially outside of the third end portion. And a second support portion extending between the third end portion and the fourth end portion, wherein the second end portion and the fourth end portion are arranged in a circumferential direction. Facing each other.

  According to this invention, the edge part of a radial direction outer side connects the 1st support part and the 2nd support part. That is, the first support part and the second support part form a shape bent outward in the radial direction when viewed from the axial direction. For this reason, when the adjacent core pieces are bent inward in the radial direction, the first support portion and the second support portion do not hinder the bending. That is, at the time of manufacturing the stator, it can be easily bent into an annular shape with a plurality of arranged core pieces connected.

FIG. 1 is a longitudinal sectional view of a motor. FIG. 2 is a flowchart showing the manufacturing procedure of the stator. FIG. 3 is a top view of a linear stator core. FIG. 4 is a top view of a stator core on which an insulator is injection-molded. FIG. 5 is a perspective view of a stator core in which an insulator is injection-molded. FIG. 6 is a perspective view showing the configuration of the connecting portion and the holding portion. FIG. 7 is a perspective view of an annular stator. FIG. 8 is a top view of the annular stator. FIG. 9 is a diagram showing the connecting portion in a state where it is not broken even when it is bent. FIG. 10 is a view showing a part of a stator in which a holding portion is provided in each adjacent insulator piece.

  Hereinafter, exemplary embodiments of the present invention will be described with reference to the drawings. In this application, the direction parallel to the central axis of the motor is the “axial direction”, the direction orthogonal to the central axis of the motor is the “radial direction”, and the direction along the arc centered on the central axis of the motor is the “circumferential direction”. , Respectively. Further, in the present application, the shape and positional relationship of each part will be described with the axial direction as the vertical direction and the circuit board side with respect to the stator as the upper side. However, the definition of the vertical direction is not intended to limit the orientation of the motor according to the present invention during manufacture and use.

<1. Motor structure>
FIG. 1 is a longitudinal sectional view of the motor 1. The motor 1 is a so-called inner rotor type molded motor in which a rotor 32 is arranged on the inner side in the radial direction of a later-described stator 21 covered with resin. The motor 1 is used for home appliances such as an air conditioner, for example. However, the motor 1 may be used for applications other than home appliances. For example, the motor 1 may be mounted on transport equipment such as an automobile or a railway, OA equipment, medical equipment, tools, industrial large equipment, and the like to generate various driving forces.

  The motor 1 has a stationary part 2 and a rotating part 3. The stationary part 2 is fixed to a frame of a device to be driven. The rotating part 3 is supported by the stationary part 2 so as to be rotatable around a central axis 9 extending vertically.

  The stationary part 2 includes a stator 21, a holder part 22, a cover 23, a circuit board 24, a lower bearing part 25, and an upper bearing part 26. The rotating unit 3 includes a shaft 31 and a rotor 32.

  The stator 21 is an armature that generates a magnetic flux in accordance with a drive current supplied from an external power source (not shown) via the circuit board 24. The stator 21 surrounds the center axis 9 extending vertically in an annular shape. The stator 21 includes a stator core 211, an insulator 212, and a plurality of coils 213.

  The stator core 211 is a magnetic body that surrounds the central shaft 9 in an annular shape. The stator core 211 is constituted by a plurality of core pieces 40 arranged in a ring shape in the circumferential direction. The stator core 211 includes 12 core pieces 40. Each core piece 40 includes a core back 41 extending in the circumferential direction and a tooth 42 projecting radially inward from the core back 41. The plurality of core backs 41 are arranged in an annular shape substantially coaxial with the central axis 9. The plurality of teeth 42 are arranged at equal intervals in the circumferential direction. For the stator core 211, for example, a laminated steel plate is used.

  The insulator 212 is attached to the stator core 211. As a material of the insulator 212, a resin which is an insulator is used. The insulator 212 covers at least a part of the stator core 211. Specifically, the insulator 212 covers both end surfaces of the teeth 42 in the axial direction and both surfaces in the circumferential direction.

  The coil 213 includes a conductive wire wound around the teeth 42 via an insulator 212. That is, the insulator 212 is interposed between the tooth 42 and the coil 213. Thereby, the electrical short circuit between the teeth 42 and the coil 213 is prevented. The detailed configuration of the stator 21 will be described later.

  The holder portion 22 is a resin member and integrally covers the stator. The holder part 22 includes a wall part 221, a bottom plate part 222, and a lower bearing holding part 223. The wall portion 221 extends in a substantially cylindrical shape in the axial direction. At least a part of the surfaces of the stator 21 and the insulator 212 is covered with a resin constituting the wall portion 221.

  The bottom plate portion 222 spreads in a plate shape from the lower end of the wall portion 221 toward the radially inner side. The bottom plate portion 222 is located on the lower side in the axial direction than the stator 21 and the rotor 32. The lower bearing holding portion 223 extends from the inner end of the bottom plate portion 222 and holds the lower bearing portion 25. In addition, the lower bearing part 25 may be hold | maintained directly with respect to the holder part 22, and may be hold | maintained via another component. The lower bearing portion 25 and the lower end portion of the shaft 31 are disposed on the radially inner side of the lower bearing holding portion 223.

  The cover 23 is located above the holder part 22 and covers the opening above the holder part 22. The circuit board 24 and the rotor 32 are accommodated in the internal space of the housing constituted by the holder portion 22 and the cover 23. The cover 23 has an upper plate portion 231 and an upper bearing holding portion 232. The upper plate portion 231 extends substantially perpendicular to the central axis 9 on the upper side in the axial direction from the stator 21, the holder portion 22, the circuit board 24, and the rotor 32. The upper bearing holding portion 232 extends from the inner end of the upper plate portion 231 and covers a part of the upper bearing portion 26. The upper bearing portion 26 and a part of the shaft 31 are disposed on the radially inner side of the upper bearing holding portion 232.

  Note that the cover 23 of the present embodiment is made of resin. The resin cover 23 can be efficiently manufactured by molding using a mold. In addition, the occurrence of the electrolytic corrosion phenomenon in the upper bearing portion 26 can be suppressed as compared with the case where a metal cover is used.

  The circuit board 24 is held by the holder portion 22 and is disposed substantially perpendicular to the central axis 9. The circuit board 24 is accommodated in a housing constituted by the holder portion 22 and the cover 23. The circuit board 24 is disposed above the stator 21 and the rotor 32. The coil 213 of the stator 21 and the circuit board 24 are electrically connected via terminal pins 27 fixed to the insulator 212.

  A connection hole 201 is provided in a part in the circumferential direction between the holder portion 22 and the cover 23. The lead wire 241 extending from the circuit board 24 passes through the connection hole 201 and is drawn out of the holder portion 22. Then, the end of the lead wire 241 is connected to an external power source. The current supplied from the external power source flows to the coil 213 through the lead wire 241, the circuit board 24, and the terminal pin 27.

  The lower bearing portion 25 supports the shaft 31 to be rotatable below the rotor 32. The upper bearing portion 26 rotatably supports the shaft 31 above the rotor 32. Ball bearings for rotating the outer ring and the inner ring relative to each other via a sphere are used for the lower bearing portion 25 and the upper bearing portion 26 in the present embodiment. The outer ring of the lower bearing portion 25 is fixed to the lower bearing holding portion 223 of the holder portion 22. The outer ring of the upper bearing portion 26 is fixed to the upper bearing holding portion 232 of the cover 23. The inner rings of the lower bearing portion 25 and the upper bearing portion 26 are fixed to the shaft 31. However, instead of the ball bearing, other types of bearings such as a slide bearing and a fluid bearing may be used for the lower bearing portion 25 and the upper bearing portion 26.

  The shaft 31 is a columnar member that extends through the rotor 32 in the axial direction. The shaft 31 rotates about the central axis 9. The upper end portion of the shaft 31 protrudes upward from the holder portion 22 and the cover 23. For example, a fan for an air conditioner is attached to the upper end portion of the shaft 31. However, the upper end portion of the shaft 31 may be coupled to a drive unit other than the fan via a power transmission mechanism such as a gear.

  The rotor 32 is a member that is fixed to the shaft 31 and rotates together with the shaft 31. The rotor 32 is disposed inside the stator 21 in the radial direction. The rotor 32 is an annular member formed of a plastic resin mixed with a magnet. The rotor 32 includes an inner cylinder part 321, an outer cylinder part 322, and a connecting part 323.

  The inner cylinder part 321 is a substantially cylindrical part fixed to the shaft 31. A spiral groove 311 is provided on at least a surface of the outer peripheral surface of the shaft 31 that is fixed to the inner cylindrical portion 321. The rotor 32 is formed by injection molding using the shaft 31 as an insert part. At the time of injection molding, the resin in a fluid state flows into a groove 311 provided on the outer peripheral surface of the shaft 31. Thereby, the rotor 32 is firmly fixed to the shaft 31. Further, relative rotation of the rotor 32 with respect to the shaft 31 is suppressed when the motor 1 is driven.

  The outer cylinder part 322 is a substantially cylindrical part located radially outside the inner cylinder part 321. The outer peripheral surface of the outer cylindrical portion 322 is a magnetic pole surface, and faces the end surface on the radially inner side of the tooth 42 in the radial direction with a slight gap. The connection part 323 is a disk-shaped part that connects the inner cylinder part 321 and the outer cylinder part 322. The thickness in the radial direction of the inner cylindrical portion 321 and the outer cylindrical portion 322 is the largest in the vicinity of the boundary with the connecting portion 323. Moreover, the radial thickness of the inner cylinder part 321 and the outer cylinder part 322 is gradually reduced toward both ends in the axial direction.

  In the present embodiment, the rotor 32 is made of a plastic resin containing a magnet. However, the rotor may be one in which a plurality of magnets are arranged on the outer peripheral surface of a cylindrical rotor core that is a magnetic body. Alternatively, the rotor may be one in which a plurality of axial holes are provided in a magnetic rotor core, and a magnet is disposed in the holes.

  When the motor 1 is driven, a drive current is supplied to the coil 213 from an external power source via the lead wire 241, the circuit board 24, and the terminal pin 27. Thereby, magnetic flux is generated in the plurality of teeth 42 of the stator core 211. A circumferential torque is generated by the action of the magnetic flux between the teeth 42 and the rotor 32. As a result, the rotating unit 3 rotates about the central axis 9.

<2. Stator Configuration and Manufacturing Procedure>
Next, a detailed configuration of the stator 21 will be described while explaining a manufacturing procedure of the stator 21.

  FIG. 2 is a flowchart showing a manufacturing procedure of the stator 21.

  At the time of manufacturing the stator 21, a linear stator core is formed (step S1). FIG. 3 is a top view of the linear stator core 211A.

  The stator core 211 </ b> A includes a first core piece group 51 and a second core piece group 52. The first core piece group 51 and the second core piece group 52 are arranged in a straight line. Each of the first core piece group 51 and the second core piece group 52 is formed by arranging a plurality of core pieces 40 each having a core back 41 and a tooth 42 in a straight line. Since the 1st core piece group 51 and the 2nd core piece group 52 are the same structures, the 1st core piece group 51 is demonstrated here.

  The first core piece group 51 includes a core piece 401, a core piece 402, a core piece 403, a core piece 404, a core piece 405, and a core piece 406, which are arranged in a straight line. The core backs 41 of the core pieces 401, 402, 403, 404, 405, 406 are arranged in a straight line. Each of the teeth 42 extends in a direction orthogonal to the arrangement direction of the core backs 41.

  Here, the linear stator core 211 </ b> A is bent into an annular shape in a later step, so that the annular stator core 211 is formed. That is, the arrangement direction of the core backs 41 becomes the circumferential direction when bent in an annular shape. In the following description up to step S4, a direction orthogonal to the arrangement direction of the core backs 41 is referred to as a “radial direction”. And the teeth 42 side with respect to the core back 41 is called radial inner side, and the other side is called radial direction outer side. The arrangement direction is also the “tangential direction perpendicular to the radial direction” in the present application.

  The radially outer surface 411 of the core back 41 of each of the core pieces 401, 402, 403, 404, 405, and 406 has an arc shape in which at least a part protrudes radially outward. In addition, the end surfaces 412 on both sides in the arrangement direction of the core backs 41 are flat surfaces inclined toward the teeth 42. The interval between the adjacent end faces 412 is gradually separated from the radially outer side toward the radially inner side.

  The core pieces 401, 402, 403, 404, 405, 405, and 406 arranged in a straight line are formed by punching electromagnetic steel sheets and stacking the punched electromagnetic steel sheets. The lamination direction of the electromagnetic steel sheets is the “axial direction” described above. In each of the laminated electromagnetic steel sheets, the core backs of adjacent core pieces are connected at the boundary portion between the radially outer side surface 411 and the end surface 412. That is, in the formed first core piece group 51, each of the core pieces 401, 402, 403, 404, 405, and 406 has a configuration in which the core backs 41 are connected to each other at the circumferential end and the radially outer end. .

  A concave portion 81 that is recessed in the arrangement direction (circumferential direction) is provided on one end surface in the circumferential direction of the core piece 406. The end surface on one side in the circumferential direction of the core piece 406 is an end surface 412 opposite to the core piece 405 side in the arrangement direction. The other end surface in the circumferential direction of the core piece 401 has a convex portion 82. The end surface on the other side in the circumferential direction of the core piece 401 is an end surface 412 of the core piece 401 on the side opposite to the core piece 402 side in the arrangement direction.

  When the linear stator core 211A is formed into an annular shape in step S4 described later, the core piece 401 of the first core piece group 51 and the core piece 406 of the second core piece group 52 are adjacent to each other in the circumferential direction. Further, the core piece 406 of the first core piece group 51 and the core piece 401 of the second core piece group 52 are adjacent to each other in the circumferential direction. Then, when the core piece 401 and the core piece 406 are adjacent to each other, the convex portion 82 is fitted into the concave portion 81. The core piece 406 is an example of the “first core piece” in the present application. The core piece 401 is an example of the “second core piece” in the present application.

  In step S1, the first core piece group 51 and the second core piece group 52 formed as described above are arranged linearly.

  Subsequently, the insulator 212 is injection-molded using the stator core 211A arranged linearly in step S1 as an insert part (step S2). FIG. 4 is a top view of the stator core 211A on which the insulator 212 is injection-molded. FIG. 5 is a perspective view of the stator core 211A in which the insulator 212 is injection-molded.

  In step S2, first, the first core piece group 51 and the second core piece group 52 are arranged inside the mold as insert parts. Then, the molten resin is poured into the mold to cure the molten resin. Thereby, each of the core pieces 401, 402, 403, 404, 405, 406 is covered with the resin insulator 212.

  The insulator is composed of a plurality of insulator pieces that respectively cover the plurality of core pieces. Hereinafter, the insulator that covers the core piece 401 is referred to as an insulator piece 501. Similarly, an insulator that covers the core piece 402 is referred to as an insulator piece 502. The insulator that covers the core piece 403 is referred to as an insulator piece 503. The insulator that covers the core piece 404 is referred to as an insulator piece 504. The insulator that covers the core piece 405 is referred to as an insulator piece 505. The insulator that covers the core piece 406 is referred to as an insulator piece 506.

  Each insulator piece includes a stator core, specifically, an upper resin portion 61 that covers the upper end portion in the axial direction of the core back 41, a lower resin portion 62 that covers the lower surface in the axial direction of the core back 41, and the upper and lower surfaces of the teeth 42. And the teeth cover part 63 which covers the both sides | surfaces of an arrangement direction (circumferential direction), the collar part 64 extended up and down from the radial direction inner end of the teeth cover part 63, and the wall extended up and down from the radial direction outer end of the teeth cover part 63 Part 65.

  When forming the coil 213, the conducting wire is wound around the teeth 42 between the flange portion 64 and the wall portion 65 via the teeth cover portion 63. That is, the collar part 64 and the wall part 65 are members that prevent the positional deviation of the coil 213. The wall 65 is an example of the “first wall” in the present application.

  The insulator 212 includes a connecting part 67 and a holding part 68. The connecting portion 67 is a member that connects adjacent insulator pieces. 4 and 5, the upper resin portion 61 of the insulator piece 501 of the second core piece group 52 and the upper resin portion 61 of the insulator piece 506 of the first core piece group 51 are connected. The holding portion 68 is provided on the insulator piece 506 of the first core piece group 51. One end (third end 721 described later) of the connecting portion 67 is directly connected to the insulator piece 501 of the second core piece group 52. Further, the other end (first end 711 described later) of the connecting portion 67 is connected to the insulator piece 506 of the first core piece group 51 by being attached to the holding portion 68. The connecting portion 67 may be the same member as the insulator piece 501 of the second core piece group 52 or may be a separate member.

  The insulator piece 506 of the first core piece group 51 is an example of the “first insulator piece” in the present application. The insulator piece 501 of the second core piece group 52 is an example of the “second insulator piece” in the present application.

  FIG. 6 is a perspective view showing the configuration of the connecting portion 67 and the holding portion 68. FIG. 6 shows a state where the connecting portion 67 is not attached to the holding portion 68. Moreover, in FIG. 6, illustration of the insulator piece 501 of the 2nd core piece group 52 to which the end of the connection part 67 is connected is abbreviate | omitted.

  The holding portion 68 is the upper resin portion 61 of the insulator piece 506 and is provided along the wall portion 65. The holding part 68 has a groove 681 provided along the tangential direction (arrangement direction) orthogonal to the radial direction from the end part in the arrangement direction (circumferential direction) facing the insulator piece 501. The groove 681 is an example of the “first groove portion” in the present application.

  The wall surface on the radially inner side of the groove 681 is a part of the wall portion 65. That is, in the upper resin portion 61, there is no sufficient space at the radially outer position from the wall portion 65, so that the wall portion 65 serves as the wall surface of the groove 681, so that the space can be effectively used.

  Further, the groove 681 opens upward in the axial direction. By opening the groove 681 on the upper side in the axial direction, the groove 681 can be formed only by a mold that is aligned in the axial direction without requiring a mold that is aligned in the radial direction at the time of injection molding of the insulator 212. However, the groove 681 does not have to be open on the upper side in the axial direction.

  The connecting part 67 has a first support part 71 and a second support part 72.

  The first support portion 71 has a first end 711 and a second end 712. The first end 711 extends in the arrangement direction. The first end portion 711 is connected to the insulator piece 506 of the first core piece group 51 by being inserted into the groove 681. The second end portion 712 is located on the insulator piece 501 side of the second core piece group 52 and on the radially outer side than the first end portion 711. The first support portion 71 extends between the first end 711 and the second end 712.

  The second support portion 72 has a third end 721 and a fourth end 722. The third end portion 721 is directly connected to the upper resin portion 61 of the insulator piece 501 of the second core piece group 52. The fourth end 722 is located on the insulator piece 506 side of the first core piece group 51 and on the radially outer side than the third end 721. The second support portion 72 extends between the third end portion 721 and the fourth end portion 722.

  The second end portion 712 of the first support portion 71 and the fourth end portion 722 of the second support portion 72 face each other in the circumferential direction. More specifically, the second end portion 712 of the first support portion 71 and the fourth end portion 722 of the second support portion 72 are connected. That is, the 1st support part 71 and the 2nd support part 72 are comprised by one member. And the connection part 67 has the shape bent at the connection part (henceforth a refractive part) of the 1st support part 71 and the 2nd support part 72. FIG. The refracting portion is a portion where the second end portion 712 of the first support portion 71 and the fourth end portion 722 of the second support portion 72 face each other in the circumferential direction. The refracting portion of the connecting portion 67 is located on the radially outer side than the core piece. In addition, the refracting portion of the connecting portion 67 is positioned so as to overlap in the radial direction with the boundary portion between the core piece 406 of the first core piece group 51 and the core piece 401 of the second core piece group 52 that are adjacent in the arrangement direction (circumferential direction) It is in.

  The first end 711 is inserted into the groove 681 along the arrangement direction. When the first end portion 711 is inserted into the groove 681, the first end portion 711 and the third end portion 721 are stressed in a direction approaching each other. Due to this stress, the angles of the first support portion 71 and the second support portion 72 are deformed, and there is a possibility of breaking before the winding process described later.

  The first end portion 711 and the third end portion 721 each have a facing surface 711A and a facing surface 721A that face each other in the arrangement direction. The facing surface 711A and the facing surface 721A are flat surfaces along the radial direction. At this time, the first end 711 is inserted into the groove 681 with a jig sandwiched between the facing surface 711A and the facing surface 721A. Thereby, the deformation | transformation of the angle of the 1st support part 71 and the 2nd support part 72 can be suppressed. Then, the first end 711 can be inserted into the groove 681 without breaking the connecting portion 67. Note that the jig is removed after the first end 711 is inserted into the groove 681.

  An uneven portion 73 is provided on the radially inner surface of the first end portion 711. Further, when the first end portion 711 is inserted into the groove 681, the uneven portion 682 is also provided on the wall surface of the groove 681 that faces the radially inner surface of the first end portion 711. When the first end portion 711 is inserted into the groove 681, the uneven portion 73 and the uneven portion 682 mesh with each other. For this reason, the first end portion 711 of the first support portion 71 inserted into the groove 681 is less likely to come off in the arrangement direction. As a result, the connecting portion 67 and the insulator piece 506 can be firmly connected.

  Moreover, the opening part of the arrangement | sequence direction (circumferential direction) edge part of the groove | channel 681 is a shape which gradually spreads to radial direction outer side. When the first end 711 is inserted into the groove 681, the first end 711 can be inserted into the groove 681 along the opening even if the insertion position is displaced in the radial direction. And as shown in FIG. 5, the 1st support part 71 which inclines with respect to the sequence direction and radial direction contacts the opening part which spreads gradually.

  Similarly, one end (third end 721) of the connecting portion 67 is connected to the insulator piece 501 of the first core piece group 51. The refracting portion of the connecting portion 67 is located at a position overlapping the circumferential end and the radially outer end of the core back 41 of the core piece 401 in the radial direction. The insulator piece 506 of the second core piece group 52 is provided with a holding portion 68.

  At the time of injection molding of the insulator 212, the wiring portion 50 is molded at one end of the insulator 212 in the axial direction. The wiring part 50 is arrange | positioned at the axial direction lower side of a core piece. The wiring portion 50 is wired with a conductive wire or the like that is bridged between the plurality of coils 213. The connecting portion 67 is provided on the side opposite to the wiring portion 50 in the axial direction.

  After the insulator 212 is molded, a conductive wire is wound around each tooth 42 via the tooth cover portion 63 of the insulator 212 (step S3). The conductive wire forms a coil 213 for each tooth 42. As a result, a linear stator 21A having a plurality of coils 213 is obtained. In step S3, when winding a conducting wire around the teeth 42, it is necessary to move the first core piece group 51 and the second core piece group 52 that are linearly connected to the winding machine. At this time, as described above, since the first core piece group 51 and the second core piece group 52 are firmly connected by the connecting portion 67, the first core piece group 51 and the second core piece group 52 are separated. You can avoid the fear.

  Subsequently, the linear stator 21A is bent into an annular shape (step S4). FIG. 7 is a perspective view of the annular stator 21. FIG. 8 is a top view of the annular stator 21. However, the coil 213 is not shown in FIGS.

  In step S4, each of the first core piece group 51 and the second core piece group 52 is bent at a connecting portion between adjacent core pieces. A connection part is the part connected to the circumferential direction by the circumferential direction edge part of each adjacent core back | bag 41, and a radial direction outer side edge part. When the linear stator 21A is bent in an annular shape and the plurality of core pieces 40 are arranged in an annular shape, the end faces 412 on both sides in the circumferential direction of each core back 41 become end faces orthogonal to the circumferential direction. And the end faces 412 in the circumferential direction of the adjacent core backs 41 are in contact with each other.

  As described above, by bringing the flat end surfaces 412 of the adjacent core backs 41 into contact with each other, the plurality of core pieces 40 can be accurately arranged. Therefore, in the stator core 211 after manufacture, it can suppress more that the distance from the central axis 9 of each core piece 40 varies. Further, when bending, the convex portion 82 of the core piece 401 fits into the concave portion 81 of the adjacent core piece 406. By fitting the convex portion 82 into the concave portion 81, the radial displacement between the adjacent core piece 401 and the core piece 406 is prevented.

  Further, when the stator 21A is annular, the first core piece group 51 and the second core piece group 52 are bent at the boundary portion between the core piece 406 of the first core piece group 51 and the core piece 401 of the second core piece group 52. . The refracting portion of the connecting portion 67 that connects the first core piece group 51 and the second core piece group 52 overlaps the boundary portion between the core piece 406 of the first core piece group 51 and the core piece 401 of the second core piece group 52 in the radial direction. .

  Therefore, when the first core piece group 51 and the second core piece group 52 are bent, the connecting portion 67 is bent with the refracting portion as a fulcrum. That is, the fulcrum for bending the first core piece group 51 and the second core piece group 52 and the fulcrum for bending the connecting portion 67 coincide with each other in the radial direction. For this reason, the first core piece group 51 and the second core piece group 52 can be easily bent without being obstructed by the connecting portion 67. When the linear stator 21A is annular, the second end portion 712 and the fourth end portion 722 are positioned on a boundary line connecting the mating portions of the adjacent core pieces and the central axis 9 when viewed from above.

  Furthermore, the connecting position of the insulator piece of the connecting portion 67 and the position of the refracting portion of the connecting portion 67 that becomes a fulcrum when bending are in different positions. For this reason, it can be compatible to firmly connect adjacent insulator pieces and to bend easily.

  Further, the refracting portion of the connecting portion 67 is located on the radially outer side than the radially outer surface 411 of the core piece. For this reason, compared with the case where a refracting part is located in the diameter direction inside rather than the diameter direction outside surface 411, connecting part 67 can be bent with a small stress. That is, the first core piece group 51 and the second core piece group 52 can be easily bent.

  When the connecting portion 67 is bent, the connecting portion 67 may break at the refracting portion. In this case, as shown in FIG. 8, the second end portion 712 of the first support portion 71 and the fourth end portion 722 of the second support portion 72 are separated from each other.

  In addition, when the linear stator 21 </ b> A is bent into an annular shape, one end (first end 711) of the connecting portion 67 connected to the insulator piece 501 of the first core piece group 51 is connected to the insulator piece 506 of the second core piece group 52. It inserts in the holding | maintenance part 68 provided. And the 1st core piece group 51 and the 2nd core piece group 52 are connected. Also in this case, the connecting portion 67 that connects the insulator piece 501 of the first core piece group 51 and the insulator piece 506 of the second core piece group 52 is broken at the refracting portion.

  Thus, according to this structure, at the time of manufacturing the annular stator 21, the first core piece group 51 and the second core piece group 52 are firmly connected by the connecting portion 67, and the linear stator 21A. Can be easily bent into an annular shape. Therefore, in the stator core 211 after manufacture, it can suppress that the distance from the central axis 9 of each core piece 40 varies. Moreover, in this embodiment, the connection part 67 which connects the 1st core piece group 51 and the 2nd core piece group 52 fractures | ruptures. For this reason, when the linear stator 21 </ b> A becomes the annular stator 21, no restoring force acts on the connecting portion 67. For this reason, in the annular stator 21, variations in the distance from the central axis 9 due to the restoring force of the connecting portion 67 can be suppressed.

  After bending the linear stator 21A and arranging the plurality of core pieces 40 in an annular shape, the boundary between the adjacent first core piece group 51 and the second core piece group 52 is welded (step S5). Specifically, the radially outer side surface of the boundary between the one end portion in the circumferential direction of the first core piece group 51 and the other end portion in the circumferential direction of the second core piece group 52 is welded. Furthermore, the radially outer side surface of the boundary portion between the other circumferential end of the first core piece group 51 and the circumferential one end of the second core piece group 52 is welded. Thereby, the annular stator 21 shown in FIGS. 7 and 8 is formed.

  After the welding process in step S5 is completed, a molding process for covering the stator 21 including the stator core 211, the insulator 212, and the coil 213 with a resin is performed (step S6). Specifically, the holder part 22 which is a resin mold part is molded by performing injection molding using the stator 21 as an insert part. Thus, by covering the stator 21 with the resin constituting the holder portion 22, it is possible to suppress the positional deviation of each core piece 40 after the motor 1 is manufactured.

  The stator 21 is formed by the above steps S1 to S6.

<3. Modification>
As mentioned above, although exemplary embodiment of this invention was described, this invention is not limited to said embodiment.

  For example, in the above embodiment, the case where the first support portion 71 and the second support portion 72 are broken when the connecting portion 67 is bent has been described. However, depending on the material or the like, the connecting portion 67 may be bent. May not break.

  FIG. 9 is a diagram showing a connecting portion 67 that does not break even when bent. In this case, the second end portion 712 of the first support portion 71 and the fourth end portion 722 of the second support portion 72 are connected at least partially.

  Moreover, in said embodiment, although the end (3rd end part 721) of the connection part 67 is directly connected to the insulator piece 501, it may be connected to the insulator piece 501 via the holding | maintenance part.

  FIG. 10 is a view showing a part of the stator 21B in which the holding portion 69 is provided in each adjacent insulator piece. In this case, the holding portion 69 is provided on the upper resin portion 61 of the insulator piece 501. The holding portion 69 is provided along the wall portion 65 of the insulator piece 501. The holding portion 69 has a groove 691 provided along the tangential direction (arrangement direction) perpendicular to the radial direction from the end portion in the arrangement direction (circumferential direction) facing the insulator piece 506. The wall portion 65 of the insulator piece 501 is an example of the “second wall portion” in the present application. The groove 691 is an example of the “second groove portion” in the present application.

  A wall surface on the radially inner side of the groove 691 is a part of the wall portion 65. That is, in the upper resin portion 61, there is no sufficient space at a position radially outward from the wall portion 65, so that the wall portion 65 serves as the wall surface of the groove 691, so that the space can be effectively used.

  One end (third end 721) of the connecting portion 67 is inserted into the groove 691. Thereby, the connection part 67 is connected to the insulator piece 501. The other end (first end 711) of the connecting portion 67 is inserted into the groove 681. Thereby, the connection part 67 is connected to the insulator piece 506. In the case of FIG. 10, the connecting portion 67 is a separate member from the insulator piece.

  Moreover, in said embodiment, the insulator was a resin molded product which uses a stator core as an insert component. However, an insulator may be molded separately from the stator core, and the molded insulator may be attached to the stator core.

  In the above embodiment, the stator core is formed by connecting a plurality of core piece groups including two or more core pieces. However, the plurality of core pieces constituting the stator core may all be separate parts. In that case, the boundary part of the circumferential direction of each core piece should just be connected by a connection part.

  Moreover, about the detailed shape of each member, you may differ from the shape shown by each figure of this application. Moreover, you may combine suitably each element which appeared in said embodiment or modification in the range which does not produce inconsistency.

  The present invention can be used in, for example, a stator, a motor, and a method for manufacturing a stator.

1: Motor 2: Static part 3: Rotating part 9: Center shaft 21: Stator 21A: Stator 22: Holder part 23: Cover 24: Circuit board 25: Lower bearing part 26: Upper bearing part 27: Terminal pin 31: Shaft 32 : Rotor 40: Core piece 41: Core back 42: Teeth 50: Wiring part 51: First core piece group 52: Second core piece group 61: Upper resin part 62: Lower resin part 63: Teeth cover part 64: Hook part 65: Wall Part 67: Connection part 68: Holding part 69: Holding part 71: First support part 72: Second support part 73: Concavity and convexity part 81: Concavity part 82: Convex part 201: Connection hole 211: Stator core 211A: Stator core 212: Insulator 213 : Coil 221: Wall part 222: Bottom plate part 223: Lower bearing holding part 231: Upper plate part 232: Upper bearing holding part 241: Lead 311: Groove 321: Inner cylinder part 322: Outer cylinder part 323: Connection part 401: Core piece 402: Core piece 403: Core piece 404: Core piece 405: Core piece 406: Core piece 411: Radial outer side surface 412: End face 501: Insulator piece 502: Insulator piece 503: Insulator piece 504: Insulator piece 505: Insulator piece 506: Insulator piece 681: Groove 682: Concavity and convexity 691: Groove 711: First end 711A: Opposing surface 712: Second end 721: Third end 721A: Opposing surface 722: Fourth end

Claims (22)

A stator used in a motor,
Surrounding a central axis extending vertically, a stator core that is a magnetic body,
A resin insulator covering the stator core;
With
The stator core is composed of a plurality of core pieces arranged in the circumferential direction,
The insulator is constituted by a plurality of insulator pieces covering each of the plurality of core pieces,
Of the plurality of insulator pieces, the adjacent first insulator piece and the second insulator piece are connected by a connecting portion,
The connecting portion is
A first end connected to the first insulator piece; a second end located on the second insulator piece side and radially outside the first end; and
A first support extending between the first end and the second end;
A third end connected to the second insulator piece;
A fourth end located on the first insulator piece side and radially outside of the third end; and
A second support portion extending between the third end portion and the fourth end portion;
Have
The second end portion and the fourth end portion face each other in the circumferential direction.
Stator. The stator according to claim 1,
The second end and the fourth end are connected at least in part.
Stator. The stator according to claim 1,
The second end and the fourth end are spaced apart from each other;
Stator. A stator according to any one of claims 1 to 3, wherein
The second end and the fourth end are located on the radially outer side than the core piece.
Stator. A stator according to any one of claims 1 to 4, wherein
The second end portion and the fourth end portion are located on a boundary line connecting the matching portion of the adjacent core pieces and the central axis in a top view.
Stator. A stator according to any one of claims 1 to 5, wherein
Each of the first end portion and the third end portion has opposing surfaces facing each other in the circumferential direction,
The facing surface is a plane along the radial direction.
Stator. A stator according to any one of claims 1 to 6,
Each of the first insulator piece and the second insulator piece has an upper resin portion that covers an upper end portion in the axial direction of the stator core,
The connecting portion connects the upper resin portion of the first insulator piece and the upper resin portion of the second insulator piece,
Stator. The stator according to claim 7, wherein
The first insulator piece is
The second insulator piece side has an opening, and has a first groove extending along a tangential direction orthogonal to the radial direction,
The first end portion extends in the tangential direction and is inserted into the first groove portion.
Stator. The stator according to claim 8, wherein
The opening of the first groove extends radially outward along the direction in which the first support extends.
Stator. The stator according to claim 8 or 9, wherein
The first groove and the first end are provided with irregularities that mesh with each other.
Stator. A stator according to any one of claims 6 to 10,
The core piece has a core back extending in the circumferential direction, and teeth projecting radially from the core back,
The first insulator piece is
Cover the core back and the teeth,
On the boundary line between the core back and the teeth, the first wall portion for preventing the displacement of the conducting wire,
The first groove portion is provided along the first wall portion, and has the first wall portion in part.
Stator. A stator according to any one of claims 8 to 10,
The second insulator piece is
The first insulator piece side is open and has a second groove extending along the tangential direction,
The third end portion extends in the tangential direction and is inserted into the second groove portion.
Stator. The stator according to claim 12, wherein
The opening of the second groove extends radially outward along the direction in which the second support extends.
Stator. A stator according to claim 12 or claim 13, wherein
The second groove portion and the third end portion are provided with irregularities that mesh with each other.
Stator. The stator according to any one of claims 12 to 14,
The core piece has a core back extending in the circumferential direction, and teeth projecting radially from the core back,
The second insulator piece is
Cover the core back and the teeth,
On the boundary line between the core back and the teeth, there is a second wall portion for preventing the displacement of the conducting wire,
The second groove is provided along the second wall and has the second wall in part.
Stator. A stator according to any one of claims 1 to 15,
Among the plurality of core pieces, the first core piece and the second core piece are adjacent to each other,
One end surface in the circumferential direction of the first core piece has a recess recessed in the circumferential direction,
The other end surface in the circumferential direction of the second core piece has a convex portion that fits into the concave portion,
Stator. A stator according to any one of claims 1 to 16, wherein
A wiring portion is provided at one end in the axial direction of the insulator,
The connecting portion is provided on the opposite side of the wiring portion in the axial direction.
Stator. A stator according to any one of claims 1 to 17,
The stator core is
Having a plurality of core piece groups composed of two or more core pieces;
The two or more core pieces included in the core piece group are connected at a circumferential end and a radially outer end.
The connecting portion connects adjacent core piece groups,
Stator. A stator according to any one of claims 1 to 18, comprising:
The insulator covers the teeth,
A conducting wire wound around the teeth via the insulator;
A resin mold portion covering the stator core, the insulator, and the conductive wire;
A stator. A stator according to any one of claims 1 to 19,
A rotor having a plurality of teeth facing the teeth in the radial direction and supported rotatably about the central axis;
Having a motor. A method of manufacturing a stator used in a motor,
a) forming a plurality of core pieces having a core back and teeth protruding from the core back;
b) a step of covering each core piece with a resin insulator piece;
c) A step of connecting adjacent first insulator pieces and second insulator pieces among the plurality of core pieces arranged in a straight line at a connecting portion;
d) winding a conductive wire around the teeth via the insulator piece;
e) a step of bending the plurality of core pieces into an annular shape;
Have
The connecting portion is
A first end connected to the first insulator piece; a second end located on the second insulator piece side and radially outside the first end; and
A first support extending between the first end and the second end;
A third end connected to the second insulator piece;
A fourth end located on the first insulator piece side and radially outside of the third end; and
A second support portion extending between the third end portion and the fourth end portion;
Have
The second end portion and the fourth end portion face each other in the circumferential direction.
Production method. The manufacturing method according to claim 21, wherein
The one end portion of the connecting portion extends in the arrangement direction of the plurality of core pieces,
In step c)
The one end portion of the connecting portion is inserted into the groove portion provided along the arrangement direction from the end portion of the first insulator piece facing the second insulator piece.
Production method.

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