JP6719052B2 - Insulator, electric motor, and blower - Google Patents

Description

The present invention relates to an insulator, an electric motor, and a blower device.

Conventionally, it is known to form ribs on the insulator in order to secure the insulation distance between the stator core inner diameter and the winding in order to insulate the stator core, that is, the iron core, from the wound winding.

The configuration will be described below with reference to FIG. 7.

As shown in FIG. 7, by providing the inner peripheral side ribs 111 protruding from the inner diameter side of the stator core, the insulation distance 115 between the end of the collar portion 112, which is a part of the stator core, and the winding 113 to be wound is increased. In addition, the inner side wall 114 is prevented from collapsing when the winding 113 is wound.

JP, 11-332139, A

In such a conventional insulator, since the outer circumference of the iron core is continuously covered with resin, it suffices to consider the insulation distance between only the inner circumference of the iron core and the winding. However, if the size of the iron core becomes large, it may be difficult to resin-mold the insulator integrally with the iron core, considering workability and strength of fitting. Also, when the split core is adopted, the resin on the outer periphery becomes discontinuous and voids are created, so the restriction on the insulation distance cannot be satisfied, and in general, the insulation distance is extended by using additional members, etc. The increase in costs due to the increase in the number of parts and the number of parts was an issue.

In order to achieve this object, the insulator according to the present invention has an inner rib that bulges outward from the circumferential ends of the flange portion and an outer rib that bulges outward from the circumferential ends of the yoke portion. Ribs, the inner ribs and the outer ribs are continuously provided from a front surface side forming a T-shaped portion of the iron core to a back surface side facing the front surface, and the outer ribs are outer peripheral walls forming an insulator. The inner rib is formed from the upper end to the lower end, and the inner rib is formed from the upper end to the lower end of the inner peripheral wall forming the insulator, thereby achieving the intended purpose.

According to the present invention, the number of parts can be reduced with a single material and the resin moldability can be improved, so that a low-cost, high-quality electric motor can be provided.

The top view of the electric motor which concerns on Embodiment 1 of this invention. Plan view of the stator according to Embodiment 1 of the present invention 1 is a perspective view of an insulator member and an iron core according to Embodiment 1 of the present invention. A rear view and a partial sectional view of an insulator member A according to Embodiment 1 of the present invention. A rear view and a partial sectional view of an insulator member B according to Embodiment 1 of the present invention. Partial radial cross-sectional view of the stator according to Embodiment 1 of the present invention Sectional view showing a conventional stator core

Hereinafter, embodiments of the present invention will be described with reference to the drawings. The following embodiments are examples of embodying the present invention and do not limit the technical scope of the present invention. In addition, the same reference numerals are given to the same parts throughout the drawings, and the second and subsequent explanations are omitted. Further, in each of the drawings, the description of the details of each part not directly related to the present invention is omitted.

(Embodiment 1)
A first embodiment of the present invention will be described with reference to the drawings.

First, the electric motor 15 according to the present embodiment will be described with reference to FIGS. 1 and 2. Note that FIG. 1 is a plan view of the electric motor 15 according to the present embodiment as viewed from the top surface side.

The electric motor 15 includes a rotor that rotates about a rotary shaft 17 and a stator 14 that is provided on the outer peripheral side of the rotor. Note that FIG. 1 shows a schematic structure of the electric motor 15, and an outer shell of the electric motor 15 and a rotor are omitted for convenience.

The stator 14 includes a stator core or iron core 16, the insulator 1, and the winding 13.

The iron core 16 has a cylindrical shape, and has a hollow circular shape in a sectional view, that is, a donut shape when a cross section perpendicular to the rotation axis 17 which is the central axis of the cylindrical shape is defined. The iron core 16 is configured by connecting a plurality of T-shaped portions (T-shaped portions 18 described later) in the circumferential direction, which will be described later in detail.

The insulator 1 is configured to cover the iron core 16 having a cylindrical shape by covering the iron core 16 from above and below in the axial direction of the rotating shaft 17. That is, the insulator 1 is composed of the insulator member A and the insulator member B. The insulator 1 includes an inner rib 2 and an outer rib 3, which will be described in detail later.

The winding wire 13 is a conductive wire mainly made of copper or aluminum alloy, and is wound around the plurality of T-shaped portions 18 via the insulator 1, that is, wound around the insulator 1. The winding 13 is connected to a DC power supply (not shown) or a DC power supply via an inverter circuit or the like and is energized to rotate the rotor about the rotating shaft 17.

Next, the detailed structure of the stator 14 will be described with reference to FIG. Note that FIG. 2 is a plan view of the stator 14. In FIG. 2, the winding wire 13 that constitutes the stator 14 is omitted for convenience.

In FIG. 2, the insulator 1 having substantially the same shape as the iron core 16 covers the entire circumference of the iron core 16, and the insulator 1 functions as an insulating material between the iron core 16 and the winding 13 not shown.

As shown in FIG. 2, the iron core 16 is configured by connecting a plurality of T-shaped portions 18 (eight in FIG. 2) in the circumferential direction around the rotation shaft 17. However, the iron core 16 does not necessarily need to connect a plurality of T-shaped portions 18 that can be individually disassembled, and may be integrally configured as a shape in which a plurality of T-shaped portions 18 are connected in a circular shape. This also applies to the insulator 1.

The T-shaped portion 18 includes a yoke portion 12, a tooth base portion 10, and a collar portion 11.

The yoke portion 12 is provided on the outer periphery of the iron core 16 and constitutes the outer peripheral surface of the iron core 16.

The tooth base portion 10 extends from the yoke portion 12 toward the inner peripheral side, and is provided as a rectangular portion in a cross sectional view in a cross section perpendicular to the rotating shaft 17.

The collar portion 11 is provided as a portion extending from the inner circumferential side tip portion of the tooth base portion 10 to both sides in the circumferential direction. The collar portion 11 is configured so that the thickness in the radial direction gradually becomes smaller as it goes away from the inner peripheral tip portion of the tooth base portion 10. The collar portion 11 does not contact the adjacent collar portion 11, but constitutes the inner peripheral surface of the iron core 16.

In other words, the iron core 16 is formed by connecting the cylindrical yoke portion 12 forming the outer circumference and the cylindrical collar portion 11 forming the inner circumference to the tooth base 10. The width of one tooth base portion 10 in the circumferential direction is shorter than the length of the one yoke portion 12 in the circumferential direction and shorter than the length of one collar portion 11 in the circumferential direction.

Next, the insulator member A and the insulator member B that form the insulator 1 will be described in detail with reference to FIGS. 3, 4, and 5. Note that FIG. 3 is a perspective view of the insulator member and the iron core 16. FIG. 4 is a rear view of the insulator member A1a according to the present embodiment and a sectional view taken along line AA. Further, FIG. 5 is a rear view of the insulator member B1b according to the present embodiment and a cross-sectional view taken along line BB.

The insulator 1 includes an insulator member A1a fitted from the T-shaped front surface 19 side of the T-shaped portion 18 constituting the iron core 16 toward the iron core 16, and an insulator member A1a fitted from the back surface 20 side which is the back surface of the front surface 19. B1b.

The insulator member A1a includes an outer peripheral wall 21a that abuts the inner peripheral surface of the yoke portion 12 on the outer peripheral side, an inner peripheral wall 22a that abuts the outer peripheral surface of the collar portion 11 on the inner peripheral side, an outer peripheral wall 21a and an inner peripheral wall 22a. And the overlapping portion 9a.

The outer peripheral wall 21a has a rectangular plate shape and is provided with a notch 26a from one side 24a toward the other side 25a facing the one side, and has a U-shape as a whole. The outer peripheral wall 21a is provided with outer ribs 3a on two sides 27a adjacent to one side 24a and the other side 25a over the entire side 27a (from the upper end to the lower end in FIG. 3).

The inner peripheral wall 22a has a rectangular plate shape and is provided with a notch 30a from one side 28a toward the other side 29a facing the one side, and has a U-shape as a whole. The inner peripheral wall 22a is provided with inner ribs 2a on two sides 31a adjacent to one side 28a and the other side 29a over the entire side 31a.

The connecting portion 23a connects the edge of the cutout 26a in the outer peripheral wall 21a and the edge of the cutout 30a in the inner peripheral wall 22a with the cutout directions aligned and a certain distance apart. Here, the certain distance is a distance between the inner peripheral surface of the yoke portion 12 and the outer peripheral surface of the collar portion 11, and coincides with the radial length of the tooth base portion 10. That is, the connecting portion 23a has a tunnel shape having a certain distance in the radial direction. The inner periphery of the connecting portion 23a in the tunnel shape is brought into contact with the tooth base portion 10 so that the connecting portion 23a can be fitted into the iron core 16.

The overlapping portions 9a are two thin-walled portions extending from both ends of the other side 25a of the outer peripheral wall 21a to both ends of the other side 29a of the inner peripheral wall 22a via the legs (bottom) in the tunnel shape of the connecting portion 23a. However, details will be described later.

The insulator member B1b has basically the same shape as the insulator member A1a, but the side sides thereof are shorter than the side sides 27a and 31a.

The insulator member B1b includes an outer peripheral wall 21b that contacts the inner peripheral surface of the yoke portion 12 on the outer peripheral side, an inner peripheral wall 22b that contacts the outer peripheral surface of the collar portion 11 on the inner peripheral side, an outer peripheral wall 21a and an inner peripheral wall 22b. And a overlap portion 9b.

The outer peripheral wall 21b has a rectangular plate shape and is provided with a notch 26b from one side 24b toward the other side 25b facing the one side, and has a U shape as a whole. In addition, in FIG. 3, the U-shape is shown upside down. The outer peripheral wall 21b is provided with outer ribs 3b on two sides 27b adjacent to one side 24b and the other side 25b over the entire sides 27b (from the upper end to the lower end in FIG. 3).

The inner peripheral wall 22b has a rectangular plate shape and is provided with a notch 30b from one side 28b toward the other side 29b facing the one side, and has a U-shape as a whole. The inner peripheral wall 22b is provided with an inner rib 2b on two side edges 31b adjacent to the one side 28b and the other edge 29b over the entire side edge 31b.

The connecting portion 23b connects the edge of the cutout 26b in the outer peripheral wall 21b and the edge of the cutout 30b in the inner peripheral wall 22b with the cutout directions aligned and a certain distance apart. That is, the connecting portion 23b has a tunnel shape with a certain distance in the radial direction. The inner periphery of the connecting portion 23b in the tunnel shape can be fitted into the iron core 16 by contacting the tooth base portion 10.

The overlapping portions 9b are two thin-walled portions extending from both ends of the other side 25b of the outer peripheral wall 21b to both ends of the other side 29b of the inner peripheral wall 22b via the legs of the connecting portion 23b in the tunnel shape. Details will be described later.

As shown in FIGS. 4 and 5, the insulator member A1a and the insulator member B1b each include a thick resin portion 6.

The thick resin portion 6 has a thickness of about 0.6 mm, and in order to secure an insulation distance between the iron core 16 and the winding 13, the resin thick portion 6 is provided from the inner diameter side surface of the yoke portion 12 through the side surface of the tooth base portion 10. The outer diameter side surface of the portion 11 is continuously provided in a portion facing (contacting) the iron core 16. In other words, the contact surface between the iron core 16 and the outer peripheral wall 21a, the inner peripheral wall 22a, and the connecting portion 23a is formed of the thick resin portion 6 except for the thin portion described later. Further, the contact surface between the iron core 16, the outer peripheral wall 21b, the inner peripheral wall 22b, and the connecting portion 23b is constituted by the resin thick portion 6 except for the thin portion which will be described later.

The overlapping portion 9 is engaged with the thin wall portion 7a and the thin wall portion 7b, respectively, at the portions where the insulator member A1a and the insulator member B1b are in contact with each other.

That is, for example, as shown in FIG. 4B, the thin-walled portion 7a that constitutes the overlapped portion 9a is provided from the contact surface 32 that is provided in the vicinity of the entrance of the cutout 26a and that contacts the insulator member A1a and the insulator member B1b. It extends toward the other side 25a. The thin portion 7a has a thickness of about 0.3 mm, which is about half the thickness of the thick resin portion 6 in the axial direction over the entire circumference of the overlapping portion 9a.

In addition, the thin portion 7b forming the overlapping portion 9b extends from the contact surface 32 provided near the entrance of the notch 26b toward the other side 25b, as shown in FIG. 5B, for example. .. The thin portion 7b has a thickness of 0.3 mm which is about half the thickness of the resin thick portion 6 in the axial direction over the entire circumference of the overlapping portion 9b.

When the insulator member A1a and the insulator member B1b are fitted into the iron core 16, the overlap portion 9a and the overlap portion 9b are opposed to each other and the notch 26a and the notch 26b are inserted in contact with the tooth base 10. .. After that, the thin-walled portion 7a of the insulator member A1a and the thin-walled portion 7b of the insulator member B1b facing each other are overlapped over the entire circumference of the overlapping portion 9, so that the insulator member A1a and the insulator member B1b are engaged with each other. In the overlapping portion 9, the thin portion 7a is located closer to the winding 13 side, and the thin portion 7b is located closer to the iron core 16 side. It has substantially the same thickness as the thick portion 6. With this overlapping structure, the insulator member A1a and the insulator member B1b can overlap and cover the T-shaped portion 18 without a gap.

In addition, the insulator member A1a and the insulator member B1b are an inner rib 2a and an inner rib 2b which bulge outward from the circumferential ends of the collar portion 11 and an outer rib which bulges inward from the circumferential ends of the yoke portion. The rib 3a and the outer rib 3b are provided, respectively.

Since the inner ribs 2a and the inner ribs 2b are provided over the entire side edges 31a and 31b, when the insulator 1 shown in FIG. 3(b) is formed, the T-shaped portion 18 extends from the front surface 19 to the back surface 20. It is formed continuously.

Since the outer ribs 3a and the outer ribs 3b are both provided over the side edges 27a and 27b, when the insulator 1 shown in FIG. 3(b) is formed, the front ribs 19 to the rear surface 20 of the T-shaped portion 18 are continuously formed. Formed.

The inner ribs 2 and the outer ribs 3 are thicker than the contact surface, that is, the thick resin portion 6. For example, the inner rib 2 and the outer rib 3 are thicker than the resin thick portion 6, from the viewpoint of strength to support the winding 13 to be wound, the inner rib 2 is about 1 mm, and the outer rib 3 is about 2.5 mm. Has a thickness of.

As shown in FIG. 4A, the inner rib 2a and the outer rib 3a are provided with a thin portion extending from the tip of the inner rib 2a to the tip of the outer rib 3a. The thin-walled portions corresponding to the inner ribs 2a and the outer ribs 3a are thicker than the other thin-walled portions, and are therefore distinguished as the thin-walled end portions 33. Similarly to the overlapping portion 9, the corresponding thin tip portions 33 are engaged with each other to form the inner ribs 2 and the outer ribs 3 without steps.

The inner ribs 2 and the outer ribs 3 can secure the insulation distance by the engagement of the thin end portion 33 without any void even after the engagement. In addition, it is possible to suppress the warp of the molding problem that generally occurs frequently at the end of the thin portion. This leads to prevention of a step when the insulator member A1a and the insulator member B1b are engaged with each other due to the warpage factor, so that disconnection when the winding 13 is wound can be prevented.

The inner rib 2 swells from the circumferential end portion of the collar portion 11 toward the circumferential end portion of the opposing yoke portion 12 as shown by an arrow 36 in FIGS. 4A and 5A. There is. In the case where the yoke portion 12 has a continuous integral shape, a position on the yoke portion 12 that is equidistant from the adjacent tooth base 10 is defined as a circumferential end portion.

As shown by the arrow 37 in FIGS. 4(a) and 5(a), the outer rib 3 is directed further outward than the circumferential end of the collar portion 11 facing the circumferential end of the yoke portion 12. Bulging out. The outer side includes, for example, the inner peripheral side tip 35 of the tooth base portion 10 in the adjacent T-shaped portion 18. For convenience, the tip 35 on the inner peripheral side in FIGS. 4A and 5A is the T-shaped portion 18 itself.

As described above, by providing the inner ribs 2 and the outer ribs 3 for all the insulators 1, as shown in the partial radial cross-sectional view of the stator 14 in FIG. Instead, it is possible to secure a necessary insulation distance between the iron core 16 on the yoke portion 12 side which is a non-charging portion and the iron core 16 on the collar portion 11 side and the winding 13 which is a charging portion.

The motor according to the present invention can secure an insulation distance by providing ribs on the inner peripheral side and the outer peripheral side of the insulator, which is an insulating material, to improve the assemblability of the insulator, and to prevent disconnection defects when winding the winding around the insulator. Since it can be significantly reduced, it is useful as an electric motor used in home appliances and the like.

1 Insulator 1a Insulator member A
1b insulator member B
2, 2a, 2b Inner rib 3, 3a, 3b Outer rib 6 Resin thick part 7a, 7b Thin part 9, 9a, 9b Overlap part 10 Tooth base 11 Collar part 12 Yoke part 13 Winding 14 Stator 15 Electric motor 16 Iron core 17 Rotating shaft 18 T-shaped portion 19 Front surface 20 Back surface 21a, 21b Outer peripheral wall 22a, 22b Inner peripheral wall 23a, 23b Connecting portion 24a, 24b, 28a, 28b One side 25a, 25b, 29a, 29b Other side 26a, 26b, 30a , 30b Notches 27a, 27b, 31a, 31b Sides 32 Contact surface 33 Tip thin-walled portion

Claims (8)

The yoke portion provided on the outer peripheral side, the tooth base portion extending from the yoke portion toward the inner peripheral side, and the collar portion extending on both sides in the circumferential direction from the inner peripheral end of the tooth base portion. An insulator as an insulating material for covering an iron core having a plurality of T-shaped portions provided,
Inner ribs that bulge outward from both ends in the circumferential direction of the collar portion,
An outer rib that bulges inward from both ends in the circumferential direction of the yoke portion ,
The inner rib and the outer rib are
Provided continuously from the front side forming the T-shaped portion of the iron core to the back side facing the front side,
further,
The outer rib is
Formed from the upper end to the entire lower end of the outer peripheral wall forming the insulator,
The inner rib is
An insulator formed from the upper end to the lower end of the inner peripheral wall forming the insulator. The inner rib is
In the T-shaped portion, bulges from the circumferential end portion of the flange portion toward the circumferential end portion of the opposing yoke portion,
The outer rib is
The insulator according to claim 1, wherein in the T-shaped portion, the insulator bulges further outward than a circumferential end of a flange portion facing the circumferential end of the yoke portion. The insulator according to claim 2, wherein the outer side is an inner peripheral side tip portion of a tooth base portion in an adjacent T-shaped portion. The insulator is
An insulator member A that is fitted from the front side that constitutes the T-shaped portion of the iron core;
An insulator member B that is fitted from the back side facing the front surface;
A thin portion at a tip portion of the insulator member A facing the insulator member B, which is thinner than a thickness of a contact surface that comes into contact with the tooth base portion of the iron core;
The tip end portion of the insulator member B facing the insulator member A is provided with a thin portion that is thinner than the thickness of the contact surface that comes into contact with the tooth base portion of the iron core,
The insulator according to any one of claims 1 to 3, which has an overlap structure that joins the insulator member A and the insulator B by engaging the thin portions with each other. The thin portion is
The insulator according to claim 4 , wherein the insulator is provided from a tip of the inner rib to a tip of the outer rib in a cross-sectional view in a cross section perpendicular to a rotation axis of the iron core. The inner rib and the outer rib are
Thicker than the thickness of the contact surface that contacts the tooth base of the iron core,
The thin tip portions corresponding to the inner rib and the outer rib are
The insulator according to claim 5 , wherein the insulator is thicker than the thin portion. The yoke portion provided on the outer peripheral side, the tooth base portion extending from the yoke portion toward the inner peripheral side, and the collar portion extending on both sides in the circumferential direction from the inner peripheral end of the tooth base portion. An iron core having a plurality of T-shaped portions provided,
The insulator according to claim 1, wherein the insulator is provided over the entire circumference of the iron core.
An electric motor comprising: a winding wound around the insulator. An air blower provided with the electric motor according to claim 7 .