JP7727376B2 - motor - Google Patents

Description

The present invention relates to a motor.

Conventionally, motors have multiple stator cores, with both ends of the conductors wound around each stator core physically and electrically connected to connecting members such as bus bars or circuit boards (see, for example, Patent Document 1).

JP 2011-205877 A

However, when the connecting member is a circuit board, there is room for improvement, as, for example, motor vibrations can cause the circuit board to move circumferentially relative to the stator, placing a load on the conductors routed between the stator and the circuit board.

One example of the objective of the present invention is to provide a motor that can reduce the load on the conductors routed between the stator and the circuit board.

A motor according to one aspect of the present invention includes a stator having a magnetic body, an insulator, and a coil formed of a conductor wound around the magnetic body via the insulator, and an annular substrate provided on the stator, wherein the substrate is recessed radially inward from its outer circumferential edge and has a first substrate-side recess and a second substrate-side recess adjacent to each other in the circumferential direction , and a substrate-side protrusion formed between the first substrate-side recess and the second substrate-side recess . The insulator includes a wall portion having a first insulator-side recess and a second insulator-side recess facing radially to positions where two conductors drawn from the coil are drawn out, and an insulator-side protrusion formed between the first insulator-side recess and the second insulator-side recess. The first insulator-side recess and the second insulator-side recess face the first substrate-side recess and the second substrate-side recess in the radial direction. Of the two ends of the conductor, one first end is located inside the board-side first recess, and the other second end is located inside the board-side second recess . In the radial direction, the first end and the second end of the conductor face the insulator-side first recess and the insulator-side second recess. In the axial direction, the insulator-side convex portion and the board convex portion face each other. The first end and the second end are arranged facing each other in the circumferential direction.

According to one aspect of the present invention, it is possible to reduce the load on the conductors routed between the stator and the substrate.

FIG. 1 is an external perspective view of a stator according to an embodiment. FIG. 2 is a partial exploded perspective view of the stator according to the embodiment. FIG. 3 is a vertical cross-sectional view of the stator according to the embodiment. FIG. 4 is a perspective view of the appearance of a split core that constitutes the stator. FIG. 5 is an enlarged plan view of the connection portion between the split core and the substrate. FIG. 6 is a partially exploded perspective view of the split core. FIG. 7 is a schematic cross-sectional view of the insulator and coil that constitute the split core. FIG. 8 is a schematic cross-sectional view of adjacent divided cores. FIG. 9 is a vertical cross-sectional view of the insulator. FIG. 10 is a schematic diagram showing the change in position of the conductor wire when the substrate is attached to the split core. FIG. 11A is an enlarged side view of a connection portion between a split core and a substrate. FIG. 11B is a schematic diagram showing an example of a state in which a conductor wire is soldered to a recessed portion of a substrate. FIG. 12A is an enlarged plan view of a wire connection portion in a first modified example of the embodiment. FIG. 12B is an enlarged side view of the wire connection portion. FIG. 13A is an enlarged perspective view of a wire connection portion in a second modified example of the embodiment. FIG. 13B is an enlarged side view of the wire connection portion. FIG. 14A is an enlarged perspective view of a substrate recess in a third modified example of the embodiment. FIG. 14B is an enlarged plan view of the front surface side of the recessed portion of the substrate. FIG. 14C is an enlarged plan view of the back surface side of the recessed portion of the substrate. FIG. 15 is a schematic diagram showing an example of a state in which a conductor wire is soldered to a recessed portion of a substrate in a third modified example of the embodiment. FIG. 16 is an external perspective view of a split core according to a fourth modified example of the embodiment. FIG. 17A is an enlarged side view of a connection portion between a split core and a substrate in a fourth modified example of the embodiment. FIG. 17B is an enlarged plan view of a wire connection portion in the fourth modified example of the embodiment. FIG. 18 is a schematic diagram showing a change in the position of the conductor wire when a substrate is attached to the split core in the fourth modified example of the embodiment.

Embodiments of the present invention will be described below with reference to the drawings. However, the present invention is not limited to the embodiments shown below. Furthermore, the dimensional relationships and ratios of elements in the drawings may differ from reality. Furthermore, there may be parts in which the dimensional relationships and ratios differ between drawings. Furthermore, the content described in one embodiment or variant applies, in principle, to other embodiments or variants as well.

(Embodiment)
FIG. 1 is an external perspective view of a stator according to an embodiment. FIG. 2 is a partially exploded perspective view of the stator. FIG. 3 is a longitudinal cross-sectional view of the stator. FIG. 4 is an external perspective view of a split core constituting the stator. FIG. 5 is an enlarged plan view of a connection portion between the split core and a substrate. FIG. 6 is a partially exploded perspective view of the split core. FIG. 7 is a schematic cross-sectional view of an insulator and a coil constituting the split core. FIG. 8 is a schematic cross-sectional view of adjacent split cores. FIG. 9 is a longitudinal cross-sectional view of an insulator. FIG. 10 is a schematic diagram showing a change in the position of a conductor when a substrate is assembled to the split core. FIG. 11A is an enlarged side view of a connection portion between the split core and a substrate. FIG. 11B is a schematic diagram showing an example of a state in which a conductor is soldered to a recess in a substrate.

For convenience, in the following description, the axial direction shown in the figure is the direction of the rotational axis of the motor in this embodiment. One of the axial directions is referred to as the first direction, and the other as the second direction. The radial direction shown in the figure is the radial direction perpendicular to the direction of the rotational axis of the motor in this embodiment. Of the radial directions, the direction away from the rotational axis X shown in the figure is referred to as the radially outward direction, and the direction toward the rotational axis X is referred to as the radially inward direction. The circumferential direction shown in the figure is the direction that coincides with the rotational direction of the motor in this embodiment.

The stator 1 according to this embodiment is applied to, for example, an inner rotor type brushless motor. The motor of this embodiment includes an inner rotor, which is a rotor, a shaft fixed to the inner rotor, a stator 1 having a coil and a magnetic body around which the coil is wound, and an annular substrate 2 attached to the stator 1. Note that motors to which the stator 1 is applied are not limited to brushless motors.

The stator 1 shown in Figure 1 is arranged to surround an inner rotor (not shown). As shown in Figure 4, the stator 1 includes a plurality of split cores 10, which are so-called split cores. The stator 1 is made up of a plurality of split cores 10 arranged in a circular ring shape along the circumferential direction, with adjacent split cores 10 joined together to form an integrated unit. As shown in Figure 2, the stator 1 has a substrate 2 formed in a circular ring shape arranged on the first axial direction side. The multiple split cores 10 are integrally molded, for example, by insert molding, while being arranged in a circular ring shape along the circumferential direction.

As shown in Figures 3 and 4, the split core 10 comprises a stator core 11, an insulator 12, and a coil 13 that surrounds the stator core 11 via the insulator 12.

The stator core 11 is a magnetic material having a laminated structure, for example, made up of multiple stacked electromagnetic steel sheets. The multiple stator cores 11 are arranged in a circular ring shape along the circumferential direction. The stator core 11 has teeth 11a and yokes 11b. The teeth 11a extend radially inward from the inner periphery of the yokes 11b. As shown in Figure 8, when the multiple split cores 10 are arranged in a circular ring shape along the circumferential direction, the yokes 11b are connected to adjacent yokes 11b in the circumferential direction.

The insulator 12 is formed, for example, from an insulating material and is interposed between the stator core 11 and the coil 13 to provide electrical insulation. As shown in FIG. 6, the insulator 12 has an accommodating portion 121 that accommodates the stator core 11 therein, and a wall portion 122 formed at the radially outer end of the accommodating portion 121. The insulator 12 is formed so that it can be separated into two pieces, and can accommodate the stator core 11 inside when separated.

The wall portion 122 is located on the outer periphery of the substrate 2 when the substrate 2 is assembled to the stator 1. When viewed radially, the wall portion 122 is formed in a roughly rectangular shape and protrudes from the yoke portion 11b in the axial direction. The wall portion 122 has two recesses that face each other radially at the positions where the two conductors 14 are pulled out from the coil 13. Specifically, as shown in FIG. 9, the wall portion 122 has a first insulator-side recess 126 and a second insulator-side recess 127.

The insulator-side first recess 126 (third recess) is formed corresponding to one of the lead-out positions of the conductor 14, with one conductor 14 positioned inward in a direction intersecting the extension direction of the conductor 14. The insulator-side second recess 127 (fourth recess) is formed corresponding to the other lead-out position of the conductor 14, with the other conductor 14 positioned inward in a direction intersecting the extension direction of the other conductor 14. As shown in Figures 5 and 11A, the insulator-side first recess 126 and the insulator-side second recess 127 are formed in the split core 10 at positions facing the lead-out positions of the conductor 14 drawn from the coil 13. Specifically, the insulator-side first recess 126 is formed in the split core 10 at a position facing the first end 141 of the conductor 14 drawn from the coil 13. The insulator-side second recess 127 is formed in the split core 10 at a position facing the second end 142 of the conducting wire 14 drawn from the coil 13. An insulator-side protrusion 128 is formed circumferentially between the insulator-side first recess 126 and the insulator-side second recess 127. The insulator-side protrusion 128 extends outward without protruding from the axial end of the wall portion 122 in the first direction. The insulator-side protrusion 128 faces the board protrusion 23 in the axial direction when the board 2 is assembled to the stator 1.

Furthermore, the insulator-side first recess 126 and the insulator-side second recess 127 face the board-side first recess 21 and the board-side second recess 22, respectively, of the board 2 in an assembled state in which the board 2 is assembled to the stator 1. Specifically, the insulator-side first recess 126 faces the board-side first recess 21 in an assembled state in which the board 2 is assembled to the stator 1. The insulator-side second recess 127 faces the board-side second recess 22 in an assembled state in which the board 2 is assembled to the stator 1. The insulator-side first recess 126 and the insulator-side second recess 127 form spaces for allowing the first end 141 and the second end 142 of the conductor 14 to escape radially outward when the conductor 14 drawn out from the coil 13 is connected to the board 2. The first substrate-side recess 21 and second substrate-side recess 22 of the substrate 2 form a space for joining the first end 141 and second end 142 of the conducting wire 14 to the substrate 2 when connecting the conducting wire 14 drawn out from the coil 13 to the substrate 2.

The accommodation portion 121 is formed into a rectangular cylindrical shape when viewed radially, and when the insulator 12 is assembled to the stator core 11, the teeth 11a are accommodated inside (Figure 6). The accommodation portion 121 has four outer surfaces 125 on its outer periphery. The conductor wire 14 is wound around the outer surfaces 125. The outer surfaces 125 are surrounded by multiple layers of coils 13. In this embodiment, the outer surfaces 125 are surrounded by two layers of coils 13, as shown in Figures 7 and 8. Of the four outer surfaces 125, two surfaces on both circumferential sides are composed of flat surfaces only, and two surfaces on both axial sides are composed of multiple recesses 130 and flat surfaces 131. Note that in this embodiment, multiple recesses and flat surfaces 131 are formed on two surfaces, but it is sufficient to form them on at least one surface.

The multiple recesses 130 are formed radially outward on two of the four outer surfaces 125 of the accommodating portion 121, one on each axial side. The recesses 130 are arranged continuously along the radial direction. Each recess 130 protrudes, for example, toward the first axial direction and is surrounded by two radially adjacent protrusions 132. Each recess 130 stores the conductor 14 wound around the insulator 12. As shown in FIG. 7 , the position of the conductor 14 wound around the multiple recesses 130 is restricted by each recess 130, and the conductor 14 is arranged evenly and in a grid pattern along the teeth 11a of the stator core 11.

The flat surfaces 131 are formed on the radially inward side of two of the four outer surfaces 125 of the accommodating portion 121, one on each axial side (Figure 7). The flat surfaces 131 are formed on the radially inward side of the outer surface 125, which has multiple recesses 130 formed on the radially outward side, and are flat surfaces on which no recesses 130 are formed. The radial length of the flat surfaces 131 is set to be longer than the outer diameter of the conductor 14.

A portion of the conductor 14 wound around the flat surface 131 is radially spaced apart between adjacent conductors 14 in the first layer of the coil 13. Specifically, the conductors 14a and 14b in the first layer of adjacent coils 13 are not in contact with each other but are radially spaced apart (Figure 7). On the other hand, the portions of the conductor 14 fitted into the multiple recesses 130 are not radially spaced apart between adjacent conductors 14 in the first layer of the coil 13 but are in contact with each other.

The portions of the conductors 14 that face the two flat surfaces 131 of two circumferentially adjacent insulators 12 face each other. Specifically, of the two adjacent insulators 12, the conductors 14a to 14c that face the flat surface 131 of one insulator 12 face the conductors 14a to 14c that face the flat surface 131 of the other insulator 12 in the circumferential direction, as shown in Figure 8.

The portion of the conductor 14 stacked on the portion of the conductor 14 facing the flat surface 131 is positioned circumferentially inward relative to the portion of the conductor 14 stacked on the portion of the conductor 14 fitted into the multiple recesses 130. Specifically, as shown in FIG. 7 , the ninth turn of the conductor 14b in the first layer of the coil 13 is shifted radially inward, and the tenth turn of the conductor 14c, the first winding of the second layer, is wound so that it is positioned circumferentially more inward (e.g., toward the second axial direction) than usual. In other words, the maximum axial height of the second-layer conductor 14c stacked on the flat surface 131 is lower than the maximum axial height of the second-layer conductor 14 stacked on the recess 130 side. Furthermore, the axial distance between the central axis of the second-layer conductor 14c and the flat surface 131 is shorter than the distance between the central axis of the second-layer conductor 14 stacked on the recess 130 side and the outer surface 125.

A portion of the conductor 14 stacked on top of the portion of the conductor 14 fitted into the multiple recesses 130 is exposed to the outside, while a portion of the conductor 14 facing the flat surface 131 is exposed to the outside. Specifically, of the conductors 14a-14c facing the flat surface 131, conductor 14a is not shielded from the outside by conductor 14c, etc., which constitute the second layer of the coil 13, as shown in Figure 7, and can be seen from the outside.

The portion of the conductor 14 facing the flat surface 131 is positioned further away from the outer surface 125 than the portion of the conductor 14 fitted into the multiple recesses 130. Specifically, conductor 14c, which is the portion of the conductor facing the flat surface 131, is stacked between conductors 14a and 14b, and is therefore positioned further away from the outer surface 125 in the first axial direction, with the distance at this time being smaller than the distance from the portion of the conductor 14 stacked on the portion of the conductor 14 fitted into the multiple recesses 130 to the outer surface 125.

As shown in FIG. 9 , the circumferential position of one of the insulator-side first recess 126 and the insulator-side second recess 127 is such that it overlaps, as viewed radially, one of a pair of circumferentially opposing outer surfaces 125 (the inner circumferential side) of the outer surfaces of the accommodating section 121. The circumferential position of the other recess is shifted circumferentially outward as viewed radially from the other of the pair of circumferentially opposing outer surfaces 125 (the outer circumferential side).

The coil 13 is formed of a conductor 14 wound around the stator core 11 via the insulator 12. The coil 13 is arranged to surround the outer surface 125 of the insulator 12. The coil 13 is wound clockwise or counterclockwise around the teeth 11a of the stator core 11 via the housing 121 of the insulator 12. The coil 13 is formed of a conductor 14 wound in two layers, but this is not limited to this. The coil 13 may be wound in, for example, two or more even layers, or one or more odd layers. The first end 141 and second end 142 of the conductor 14 of the coil 13 are drawn out in the same direction as lead wires. Both the first end 141 and the second end 142 are drawn out from the coil 13 in a first axial direction. The first end 141 is pulled out from the outer periphery of the coil 13, and its pull-out position is on the outer periphery of the coil 13. The second end 142 is pulled out from the inner periphery of the coil 13, and its pull-out position is inside the outer periphery of the coil 13.

The substrate 2 is disposed on the first axial direction side of the stator 1. The substrate 2 is formed of an insulating resin material, such as epoxy. Electronic components (not shown) are disposed on the substrate 2. The electronic components include, for example, an inverter and a control IC. As shown in Figures 2, 5, 11A, and 11B, the substrate 2 is recessed radially inward from its outer circumferential edge and has multiple substrate-side first recesses 21 and substrate-side second recesses 22 adjacent to each other in the circumferential direction.

As shown in FIG. 11A, when the substrate 2 is assembled to the stator 1, the first end 141, which is one end of the conducting wire 14 drawn from the coil 13, is inserted into the substrate-side first recess 21. As shown in FIG. 11A, when the substrate 2 is assembled to the stator 1, the second end 142, which is the other end of the conducting wire 14 drawn from the coil 13, is inserted into the substrate-side second recess 22. A substrate protrusion 23 is formed in the circumferential direction between the substrate-side first recess 21 and the substrate-side second recess 22. The substrate protrusion 23 is formed to protrude radially outward from the outer periphery of the substrate main body 20.

In an assembled state in which the board 2 is assembled to the stator 1, the first end 141 of the conducting wire 14 is located inside the board-side first recess 21, and the other end, the second end 142, is located inside the board-side second recess 22. The first end 141 and the second end 142 are arranged facing each other in the circumferential direction. The first end 141 is arranged inside the board-side first recess 21, inclined in the circumferential direction toward the board-side second recess 22. The second end 142 is arranged inside the board-side second recess 22, inclined in the circumferential direction toward the board-side first recess 21. The first end 141 and the second end 142 circumferentially sandwich the board protrusion 23 between the board-side first recess 21 and the board-side second recess 22. As shown in FIG. 11B, the first end 141 and the second end 142 are joined to the land 30 of the substrate 2, for example, by solder H, with the substrate protrusion 23 sandwiched between the substrate first recess 21 and the substrate second recess 22 in the circumferential direction.

The land 30 is conductive and is connected to the conductor 14. As shown in FIG. 11B, the land 30 is physically and electrically connected by soldering to the first end 141 and second end 142 of the conductor 14 drawn out from the coil 13. The land 30 is provided on the substrate surface 20a side.

Next, we will explain the process of winding the conductor 14 around the insulator 12 to form the coil 13 in this embodiment. When winding the conductor 14 around the insulator 12, the first layer of the coil 13 is wound from the first turn to the eighth turn along the recesses 130, with the ninth turn wound on the flat surface 131. From this state, when the second layer of the conductor 14c of the coil 13 is wound so that it is positioned between the first layer of the conductors 14a and 14b, the ninth turn, which was located at the innermost radial position of the first layer of the coil 13, moves radially inward, and the tenth turn, the first winding of the second layer, is wound so that it is positioned further toward the second axial direction than usual. In other words, because the radial position of the conductor 14 located on the flat surface 131 is not restricted, it moves due to the force generated when the second layer of the conductor 14c is wound, guiding the second layer of the conductor 14c toward the second axial direction. At this time, the ninth turn of the first layer of wire 14b facing the flat surface 131 of the insulator 12 is spaced apart from the first to eighth turns of wire 14 facing the recesses 130. Therefore, the portion of the wire 14 facing the flat surface 131 in the radial direction is spaced apart from the portion of the wire 14 fitted into the recesses 130. This allows for a wider space between the wires 14 wound around adjacent stator cores 11, as shown in Figure 8, and prevents electrical shorts caused by contact between the wires 14c of adjacent coils 13.

Next, we will explain the process of routing the first end 141 and second end 142 of the conductor 14, which is a lead wire drawn from the coil 13 in this embodiment, and assembling it into the first board-side recess 21 and the second board-side recess 22. When connecting the conductor 14 drawn from the coil 13 to the board 2, the first end 141 and second end 142 of the conductor 14 are tilted radially outward and routed inside the first insulator-side recess 126 and the second insulator-side recess 127 of the insulator 12. Next, after assembling the board 2 to the stator 1, the ends of the conductor 14 that have routed inside the first insulator-side recess 126 and the second insulator-side recess 127 are inserted inside the first board-side recess 21 and the second board-side recess 22. This allows the stator 1 and board 2 to be assembled without the conductor 14 interfering with the insulator 12.

As described above, a motor according to one aspect of the present invention includes a coil 13 formed of a conductor 14 and an insulator 12 having an outer surface 125 surrounded by the coil 13. The outer surface 125 of the insulator 12 includes a plurality of recesses 130 and a flat surface 131. A portion of the conductor 14 facing the flat surface 131 is spaced apart from a portion of the conductor 14 fitted into the plurality of recesses 130. For example, when winding the conductor 14 around the insulator 12 to form the coil 13, the first through eighth turns of the conductor 14 are wound along the plurality of recesses 130, and the ninth turn is wound around the flat surface 131. As a result, the ninth turn of the conductor 14 in the first layer is shifted radially inward, and the tenth turn of the conductor 14, which is the first winding of the second layer, is wound so that it is positioned circumferentially inward (e.g., toward the second axial direction) relative to conventional windings. In other words, because the radially inward movement of the conductor 14 wound on the flat surface 131 is not restricted, the force exerted when the 10th turn of the conductor 14 is wound causes it to move, guiding it circumferentially inward, thereby reducing the circumferential size (height) of the radially inner side of the coil 13. This prevents contact between the coils 13 formed on adjacent insulators 12.

In addition, in a motor according to one aspect of the present invention, the portions of the conductors 14 that face the two flat surfaces 131 of two adjacent insulators 12 in the circumferential direction face each other. This prevents contact between the coils 13 formed on the two adjacent insulators 12.

In addition, in a motor according to one aspect of the present invention, the portion of the conductor 14 stacked on the portion of the conductor 14 facing the flat surface 131 is positioned circumferentially inward relative to the portion of the conductor 14 stacked on the portion of the conductor 14 fitted into the multiple recesses 130. As a result, the ninth turn of the conductor 14b in the first layer of the coil 13 moves radially inward, and the tenth turn of the conductor 14c, which is the first winding of the second layer, is wound so that it is positioned more circumferentially inward than usual (for example, toward the second axial direction).

In addition, in a motor according to one aspect of the present invention, a portion of the conductor 14 that faces the flat surface 131 is exposed to the outside, compared to a portion of the conductor 14 that is stacked on top of a portion of the conductor 14 that fits into the multiple recesses 130. This causes the ninth turn of the conductor in the first layer to move radially, making it easier for the tenth turn of the conductor, which is the first turn of the second row, to be positioned more circumferentially inward than usual.

In addition, in a motor according to one aspect of the present invention, the portion of the conductor 14 facing the flat surface 131 is positioned further away from the outer surface 125 of the insulator 12 than the portion of the conductor 14 fitted into the multiple recesses 130. This makes it easier for the ninth turn of the conductor 14b in the first layer of the coil 13 to move radially.

As described above, a motor according to one aspect of the present invention has an annular substrate 2 mounted on a stator 1. The substrate 2 is recessed radially inward from its outer circumferential edge and has a first substrate-side recess 21 and a second substrate-side recess 22 adjacent to each other in the circumferential direction. Of the two ends of the conductor 14, the first end 141 is located inside the first substrate-side recess 21, and the second end 142 is located inside the second substrate-side recess 22. The first end 141 and the second end 142 of the conductor 14 are arranged facing each other in the circumferential direction. This allows the first end 141 and the second end 142 of the conductor 14 to circumferentially clamp the substrate protrusion 23 located between the first substrate-side recess 21 and the second substrate-side recess 22. This, for example, restricts circumferential movement of the substrate 2 relative to the stator 1 due to vibration, etc., and reduces the load on the conductor 14 routed between the stator 1 and the substrate 2.

In a motor according to one aspect of the present invention, the first end 141 is disposed inside the board-side first recess 21, inclined in the circumferential direction toward the board-side second recess 22, and the second end 142 is disposed inside the board-side second recess 22, inclined in the circumferential direction toward the board-side first recess 21. The first end 141 and the second end 142 circumferentially sandwich the board protrusion 23 between the board-side first recess 21 and the board-side second recess 22.

As described above, in a motor according to one aspect of the present invention, the insulator 12 includes a wall portion 122 having two recesses (insulator-side first recess 126 and insulator-side second recess 127) that face radially to two lead-out positions of the conductor 14 drawn from the coil 13. One of the two lead-out positions is located on the outer periphery of the coil 13, and the other is located inside the outer periphery. The substrate 2 is recessed radially inward from its outer periphery and has a substrate-side first recess 21 and a substrate-side second recess 22 that are adjacent in the circumferential direction. The substrate-side first recess 21 faces the insulator-side first recess 126, and the substrate-side second recess 22 faces the insulator-side second recess 127.

With the above configuration, when connecting the conductor 14 drawn from the coil 13 to the circuit board 2, the ends of the conductor 14 (first end 141, second end 142) can be routed to the radially outer recesses of the insulator 12 (insulator-side first recess 126, insulator-side second recess 127). After the circuit board 2 is assembled to the stator 1, the ends of the conductor 14 routed to the recesses of the insulator 12 can be inserted into the recesses on the circuit board 2 side (circuit board-side first recess 21, circuit board-side second recess 22). As a result, the stator 1 and circuit board 2 can be assembled without the conductor 14 interfering with the insulator 12, improving motor productivity.

In addition, in a motor according to one aspect of the present invention, the circumferential position of one of the insulator-side first recess 126 and the insulator-side second recess 127 is such that, as shown in FIG. 9 , it overlaps with one (the circumferentially inner side) of a pair of circumferentially opposing outer surfaces 125 of the outer surface of the accommodating section 121, as viewed from the radial direction. The circumferential position of the other recess is shifted circumferentially outward, as viewed from the radial direction, with respect to the other (the circumferentially outer side) of the pair of circumferentially opposing outer surfaces 125.

The insulator-side second recess 127 is formed at a position aligned with one side (inner circumferential side) of the outer surface 125 at both circumferential ends of the accommodating section 121 of the insulator 12 so that the conductor 14 at the beginning of the winding of the coil 13 can enter and exit. Meanwhile, the insulator-side first recess 126 is formed one conductor wire circumferentially outward from a position aligned with the other side (outer circumferential side) of the outer surface 125 at both circumferential ends of the accommodating section 121 of the insulator 12 so that the conductor 14 at the end of the winding of the coil 13 (the second layer of conductor 14 in this embodiment) can enter and exit. This configuration allows the ends (first end 141, second end 142) of the conductor 14 to escape to the recesses (first insulator-side recess 126, second insulator-side recess 127) of the insulator 12 located radially outward when the conductor 14 drawn out from the coil 13 is connected to the substrate 2. This allows the stator 1 and substrate 2 to be assembled without the conductor 14 interfering with the insulator 12, improving motor productivity.

(First Modification of the Embodiment)
In the above embodiment, the first end 141 of the conducting wire 14 is disposed inside the first board recess 21 at an inclination in the circumferential direction toward the second board recess 22, and the second end 142 of the conducting wire 14 is disposed inside the second board recess 22 at an inclination in the circumferential direction toward the first board recess 21, but this is not limited to this. Fig. 12A is an enlarged plan view of a connection portion in a first modified embodiment. Fig. 12B is an enlarged side view of the connection portion. The motor according to the second modified embodiment differs from the above embodiment in that the first end 141 and the second end 142 of the conducting wire 14 each have a bent portion.

As shown in Figures 12A and 12B, the first end 141 of the conducting wire 14 has a first bent portion 143 when the substrate 2 is assembled to the stator 1. The second end 142 of the conducting wire 14 has a second bent portion 144 when the substrate 2 is assembled to the stator 1. The first bent portion 143 and the second bent portion 144 are bent toward each other. The first bent portion 143 is formed at the first end 141 of the conducting wire 14, which is drawn straight from the coil 13 in the first axial direction, at a portion that protrudes from the inside of the substrate-side first recess 21 to the outside in the first axial direction. The first bent portion 143 bends in the circumferential direction of the substrate 2 from the substrate-side first recess 21 toward the substrate-side second recess 22, sandwiching the substrate protrusion 23 between them. The second bent portion 144 is formed at the second end 142 of the conducting wire 14, which is drawn straight from the coil 13 in the first axial direction, at a portion that protrudes from the inside of the board-side second recess 22 to the outside in the first axial direction. The second bent portion 144 bends in the circumferential direction of the board 2 from the board-side second recess 22 toward the board-side first recess 21, sandwiching the board protrusion 23 between them.

In a motor according to one aspect of the present invention, the first end 141 of the conductor 14 extending from the coil 13 has a first bent portion 143 bent in the circumferential direction of the substrate 2 at the portion where it protrudes from the inside of the first recess 21 on the substrate side to the outside. The second end 142 of the conductor 14 has a second bent portion 144 bent in the circumferential direction of the substrate 2 at the portion where it protrudes from the inside of the second recess 22 on the substrate side to the outside. The first bent portion 143 and the second bent portion 144 are bent in a direction facing each other. In this way, the first end 141 and the second end 142 of the conductor 14 have the first bent portion 143 and the second bent portion 144 bent inward in the circumferential direction so as to face each other, thereby holding the substrate protrusion 23 in the circumferential direction. This eliminates the need to tilt the first end 141 and the second end 142 when extending the conductor 14 from the coil 13, making it easier to connect the conductor 14 to the substrate 2.

(Second Modification of the Embodiment)
In the first modified example of the embodiment, the first end 141 and the second end 142 of the conductor 14 each have a bent portion, but this is not limited to this. Fig. 13A is an enlarged perspective view of a connection portion in the second modified example of the embodiment. Fig. 13B is an enlarged side view of the connection portion. The motor according to the second modified example of the embodiment differs from the first modified example in that the first end 141 and the second end 142 of the conductor 14 each have a bent portion and a deformed portion.

13A and 13B, the first end 141 of the conducting wire 14 has a first deforming portion 145 with a cross-sectional shape different from that of the conducting wire 14 in the assembled state in which the substrate 2 is assembled to the stator 1. The first deforming portion 145 is formed in a rectangular shape when viewed from the axial direction and is located on the second bend 144 side relative to the first bend 143. The first deforming portion 145 is, for example, a portion that is crushed circumferentially before the first end 141 is bent at the first bend 143. The second end 142 of the conducting wire 14 has a second deforming portion 146 with a cross-sectional shape different from that of the conducting wire 14 in the assembled state in which the substrate 2 is assembled to the stator 1. The second deforming portion 146 is formed in a rectangular shape when viewed from the axial direction and is located on the first bend 143 side relative to the second bend 144. The second deformed portion 146 is, for example, a portion that is crushed in the circumferential direction before the second end portion 142 is bent at the second bent portion 144.

In a motor according to one aspect of the present invention, the first end 141 of the conductor 14 is located closer to the second bend 144 than the first bend 143 and has a first deformation portion 145 with a cross-sectional shape different from that of the conductor 14. The second end 142 of the conductor 14 is located closer to the first bend 143 than the second bend 144 and has a second deformation portion 146 with a cross-sectional shape different from that of the conductor 14. As a result, by crushing and deforming the first end 141 and second end 142 of the conductor 14 in the axial direction, the axial height of the connection portion can be made lower than the outer diameter of the conductor 14. As a result, the axial height of the stator 1, including the substrate 2, can be reduced, allowing for a more compact motor.

(Third Modification of the Embodiment)
In the above embodiment, the substrate 2 has lands 30 that electrically connect the ends of the conductor wires 14 drawn from the coil 13, and the lands 30 are provided on the substrate front surface 20a side, but this is not limited to this. Fig. 14A is an enlarged perspective view of a substrate recess in a third modified embodiment. Fig. 14B is an enlarged plan view of the front surface side of the substrate recess. Fig. 14C is an enlarged plan view of the back surface side of the substrate recess. Fig. 15 is a schematic diagram showing an example of a state in which conductor wires are soldered to the substrate recess in the third modified embodiment. The motor according to the third modified embodiment differs from the above embodiment in that the lands 30 are formed not only on the front and back surfaces of the substrate main body 20 but also on the inner circumferential surfaces of each recess.

The land 30 has a first land portion 31, a second land portion 32, and a third land portion 33. The first land portion 31 is disposed on one end surface of the substrate 2 in the thickness direction. Specifically, as shown in Figures 14A and 14B, the first land portion 31 is disposed on the front surface of the substrate main body 20 along each of the substrate-side first recesses 21 and substrate-side second recesses 22. The second land portion 32 is disposed on the other end surface of the substrate 2 in the thickness direction. Specifically, as shown in Figure 14C, the second land portion 32 is disposed on the back surface of the substrate main body 20 along each of the substrate-side first recesses 21 and substrate-side second recesses 22. As shown in Figures 14A to 14C, the third land portion 33 is disposed on the inner circumferential surfaces of each of the substrate-side first recesses 21 and substrate-side second recesses 22. The first land portion 31, the second land portion 32, and the third land portion 33 are connected to each other. Specifically, in each of the first substrate recess 21 and the second substrate recess 22, the first land portion 31, the second land portion 32, and the third land portion 33 are formed continuously and electrically conductive. In the third modification of this embodiment, the first land portion 31 has a larger area than the third land portion 33. Furthermore, the second land portion 32 has a smaller area than the first land portion 31.

When the board 2 is assembled to the stator 1, the first end 141 of the conductor 14 is inserted through the inside of the board-side first recess 21 at an angle circumferentially toward the board-side second recess 22. When the board 2 is assembled to the stator 1, the second end 142 of the conductor 14 is inserted through the inside of the board-side second recess 22 at an angle circumferentially toward the board-side first recess 21. As shown in FIG. 15 , the outer peripheral surfaces of the first end 141 and second end 142 of the conductor 14 are supported by contact with the peripheral ends of the recesses (board-side first recess 21, board-side second recess 22) on the board front surface 20a side and the board back surface 20b side. This prevents the end of the conductor 14, which is the lead wire, from moving relative to the board 2.

As described above, in a motor according to one aspect of the present invention, the first board-side recess 21 and the second board-side recess 22 are recessed radially inward from their outer circumferential ends and open radially outward. This allows the ends of the conductors 14 to be routed radially into the inside of the first board-side recess 21 and the second board-side recess 22, rather than axially (perpendicular to the board surface), as opposed to through holes provided in the board 2. This facilitates assembly of the conductors 14 to the board 2 and improves productivity. Furthermore, third lands 33 are disposed on the inner circumferential surfaces of the first board-side recess 21 and the second board-side recess 22, connecting the first land 31, the second land 32, and the third land 33. This allows soldering the lands 30 to the conductors 14, not only to connect the first land 31 to the conductors 14, but also to connect the second land 32 and the third land 33 to the conductors 14. This improves the strength of the joint between the land 30 and the conductor 14, and because the conductor 14, which is the lead wire from the coil 13, is connected widely across the thickness of the substrate 2, it is possible to suppress relative movement between the substrate 2 and the conductor 14 due to, for example, motor vibration, and prevent breakage of the conductor 14.

Note that in the third modified example of the above embodiment, the first end 141 is arranged inside the first substrate recess 21, inclined circumferentially toward the second substrate recess 22, and the second end 142 is arranged inside the second substrate recess 22, inclined circumferentially toward the first substrate recess 21, but this is not limited to this. The third modified example of the embodiment may also be applied to the first and second modified examples of the embodiment.

In addition, in the third modified example of the above embodiment, by soldering to the first land portion 31 from the board surface 20a side, the end of the conductor 14 is soldered to the board 2 at three locations using solder that flows into the third land portion 33 and then the second land portion 32. However, this is not limited to this. For example, by soldering to the first land portion 31 from the board surface 20a side, the end of the conductor 14 may be soldered to the board 2 at two locations using solder that flows into the third land portion 33. Alternatively, by soldering to the first land portion 31 from the board surface 20a side and soldering to the second land portion 32 from the board back surface 20b side, the end of the conductor 14 may be soldered to the board 2 at three locations using solder that flows into the third land portion 33.

(Fourth Modification of the Embodiment)
In the above embodiment, the wall portion 122 of the insulator 12 has two recesses (insulator-side first recess 126 and insulator-side second recess 127) that radially face two lead-out positions of the conductor 14 drawn from the coil 13, but this is not limited to this. Fig. 16 is an external perspective view of a split core according to a fourth modified embodiment. Fig. 17A is an enlarged side view of a connection portion between the split core and a board according to the fourth modified embodiment. Fig. 17B is an enlarged plan view of the connection portion according to the fourth modified embodiment. Fig. 18 is a schematic diagram showing a change in the position of the conductor when a board is assembled to the split core according to the fourth modified embodiment. The motor according to the fourth modified embodiment differs from the above embodiment in that the wall portion 122A of the insulator 12A has an inclined surface 152.

As shown in FIG. 16 , the insulator 12 has a housing portion 121 and a wall portion 122A formed at the radially outer end of the housing portion 121. When the substrate 2 is assembled to the stator 1, the wall portion 122A is located on the outer periphery of the substrate 2. When viewed radially, the wall portion 122A is formed in a substantially rectangular shape and protrudes from the yoke portion 11b in the axial direction. As shown in FIG. 16 , the wall portion 122A has a recess 151 and an inclined surface 152. The recess 151 is formed so as to be recessed from the end of the wall portion 122A on the first axial direction toward the second axial direction. The recess 151 is a portion into which the substrate protrusion 23 fits when the substrate 2 is assembled to the stator 1. When viewed circumferentially, the inclined surface 152 is inclined so that its radial thickness decreases from the middle of the axial direction of the wall portion 122A toward the end on the first axial direction, as shown in FIG. 18 . Furthermore, when the substrate 2 is assembled to the stator 1, the inclined surface 152 is inclined radially from the inside to the outside in the direction in which the conductor 14 is drawn out.

As described above, in a motor according to one aspect of the present invention, the insulator 12A has a wall portion 122A located on the outer periphery of the substrate 2 when the substrate 2 is assembled to the stator 1. When the substrate 2 is assembled to the stator 1, the wall portion 122A has an inclined surface 152 that slopes radially from the inside to the outside in the direction in which the conductor 14 is drawn out. This allows the ends of the conductor 14 (first end 141, second end 142) to escape toward the inclined surface 152 of the insulator 12A, which is located radially outward, when the conductor 14 drawn out from the coil 13 is connected to the substrate 2. After the substrate 2 is assembled to the stator 1, the ends of the conductor 14 that escape toward the inclined surface 152 of the insulator 12A can then be placed in the recesses on the substrate 2 side (substrate-side first recess 21, substrate-side second recess 22). As a result, the stator 1 and substrate 2 can be assembled without the conductor 14 interfering with the insulator 12A, improving motor productivity.

In addition, in the above embodiment and modified examples, the multiple recesses 130 are formed so as to recess from the outer surface 125 toward the second axial direction, but this is not limited to this, and they may be formed so as to protrude from the outer surface 125 toward the first axial direction. Furthermore, one of the four outer surfaces 125 is composed of multiple recesses 130 and a flat surface 131, but this is not limited to this. For example, all four outer surfaces 125 may be composed of multiple recesses 130 and a flat surface 131.

In addition, in the above embodiment and modified examples, it has been described that three of the four outer surfaces 125 of the insulator 12 are composed of only flat surfaces, and one is composed of multiple recesses 130 and a flat surface 131, but this is not limited to this. For example, the outer surface 125 composed of multiple recesses 130 and a flat surface 131 may be applied to all or some of the four outer surfaces 125 that make up the outer peripheral surface of the accommodating section 121.

The above describes embodiments and variations of the present invention, but the present invention is not limited to these embodiments and variations, and various modifications are possible without departing from the spirit of the invention. Furthermore, the present invention is not limited to these embodiments and variations. The present invention also includes configurations that combine the above-mentioned components appropriately. Furthermore, further effects and variations can be easily derived by those skilled in the art. Therefore, the broader aspects of the present invention are not limited to the above embodiments, and various modifications are possible.

1 Stator, 2 Substrate, 10 Split core, 11 Stator core, 11a Teeth portion, 11b Yoke portion, 12 Insulator, 13 Coil, 14 Conductor, 20 Substrate body, 21 Substrate-side first recess, 22 Substrate-side second recess, 30 Land, 31 First land portion, 32 Second land portion, 33 Third land portion, 121 Housing portion, 122 Wall portion, 125 Outer surface, 126 Insulator-side first recess (third recess), 127 Insulator-side second recess (fourth recess), 128 Insulator-side convex portion, 130 Convex portion, 131 Flat surface, 132 Convex portion, 141 First end portion, 142 Second end portion, 143 First bent portion, 144 Second bent portion, 145 First deformation portion, 146 Second deformation portion

Claims (5)

a stator including a magnetic body, an insulator, and a coil formed by a conductive wire wound around the magnetic body via the insulator;
an annular substrate provided on the stator;
Equipped with
The substrate is
the substrate-side first recess and the substrate-side second recess are recessed radially inward from the outer peripheral end and are adjacent to each other in the circumferential direction, and the substrate-side protrusion is formed between the substrate-side first recess and the substrate-side second recess,
the insulator includes a wall portion having, in a radial direction, an insulator-side first recess and an insulator-side second recess facing positions at which two conducting wires are drawn out from the coil, and an insulator-side convex portion formed between the insulator-side first recess and the insulator-side second recess;
the insulator-side first recess and the insulator-side second recess face the board-side first recess and the board-side second recess in a radial direction;
a first end of the conductive wire is located inside the first substrate recess;
the other second end is located inside the substrate-side second recess,
the first end of the conductor and the second end of the conductor face the first insulator-side recess and the second insulator-side recess in a radial direction;
the insulator-side protrusion and the board protrusion face each other in the axial direction,
The first end and the second end are
The motors are arranged facing each other in the circumferential direction. The first end is
The inner side of the first recessed portion is inclined toward the second recessed portion in the circumferential direction,
The second end is
The inner side of the substrate-side second recess is disposed in a state inclined toward the substrate-side first recess in the circumferential direction,
The first end and the second end are
The substrate protrusion is sandwiched between the substrate-side first recess and the substrate-side second recess in the circumferential direction.
The motor according to claim 1 . The first end is
a first bent portion bent in a circumferential direction of the substrate at a portion protruding from the inside of the substrate- side first recess to the outside,
The second end is
a second bent portion bent in a circumferential direction of the substrate at a portion protruding from the inside of the substrate- side second recess to the outside,
the first bent portion and the second bent portion are bent in directions facing each other,
The motor according to claim 1 . The first end is
a first deformation portion located on the second bent portion side of the first bent portion and having a cross-sectional shape different from a cross-sectional shape of the conductor;
The second end is
a second deformation portion located on the first bent portion side of the second bent portion and having a cross-sectional shape different from the cross-sectional shape of the conductor;
The motor according to claim 3. The motor according to claim 4 , wherein the substrate protrusion is disposed between the first end and the second end of the conductor.