JP2007228667A - Stator for motors, motor, manufacturing method for motor, and air conditioner - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a stator for motors wherein a substrate is prevented from being exposed to the exterior after a stator is molded and thus there is no possibility that moisture reaches the substrate. <P>SOLUTION: The stator 100 is so constructed that a substrate 11 mounted with an electronic component is incorporated thereto. The stator includes: a stator insulating portion 24 having protrusions protruded in the axial direction; and a substrate retaining part 40 that is incorporated to the substrate 11, has protrusions 2 extended from the substrate 11 in the vertical direction when it is incorporated to the substrate 11, and is fixed to the protrusions of the stator insulating portion together with the substrate 11. When the stator 100 of a motor is molded, the protrusions 2 of the substrate retaining part 40 are held down by a molding die. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to an electric motor stator that is molded by assembling a substrate to the stator, and more particularly to a method for suppressing deformation of the substrate due to pressure during molding.

  In a stator of a molded motor equipped with a substrate, a flat circular dish-shaped cover made of synthetic resin that covers the substrate is equipped with a plurality of fitting holes on the ceiling surface and a support to prevent the cover from being dented. There has been proposed a molded motor that prevents warping and deformation of the substrate by pressing the cover and the substrate when the stator is molded (for example, see Patent Document 1).

In addition, the stator of the electric motor for assembling the wiring board to the stator has a first support column having a claw portion for locking the front side surface of the wiring substrate and a second support column supporting the back side surface of the wiring substrate. And these both support | pillars are arrange | positioned in the multiple places of the end surface of a stator. The first support column and the second support column have different pitches in the radial direction, and the wiring board is provided with a notch that engages with the first support column. A stator wiring board holding structure has been proposed in which a wall portion is provided on a molded insulator as required, and a plurality of legs are provided on the wiring board toward the wall portion (see, for example, Patent Document 2). .
JP-A-6-178514 JP 11-355996 A

  In the stator of an electric motor that mounts the substrate on the stator and molds, in order to prevent deformation of the substrate due to the pressure during molding, the substrate is directly pressed by the protrusion provided on the mold. There is a problem that moisture is permeated from the exposed portion of the substrate depending on the usage environment of the electric motor by exposing the pressed portion of the substrate.

  The present invention has been made to solve the above-described problems. An electric motor stator in which moisture is not likely to reach the substrate is prevented by preventing the substrate from being exposed to the outside after molding of the stator. The purpose is to provide.

  An electric motor stator according to the present invention is an electric motor stator on which a board on which electronic components are mounted is assembled. The electric motor stator is assembled to a board, and is clamped by a mold for molding when the electric motor stator is molded. And a board pressing part that is molded and molded.

  With the above configuration, the stator of the electric motor according to the present invention can improve quality because moisture does not easily reach the substrate because the substrate is not exposed to the outside after molding.

Embodiment 1 FIG.
1 to 7 are diagrams showing the first embodiment. FIG. 1 is a perspective view of the board holding component 40, FIG. 2 is a perspective view of the board 11, and FIG. 3 is a back surface of the board 11 assembled with the board holding component 40. FIG. 4 is a perspective view of the stator 50, FIG. 5 is a perspective view of the stator 100 of the electric motor in which the board 11 on which the board holding component 40 is assembled is assembled to the stator 50, and FIG. FIG. 7 is a view showing a manufacturing process of the electric motor 200.

  A substrate pressing component 40 shown in FIG. 1 is formed by molding a thermoplastic resin such as PBT (polybutylene terephthalate), and has a configuration in which the protrusions 2 are connected by a thin connecting portion 40a. In the example of FIG. 1, the board pressing component 40 includes nine protrusions 2.

  The end surface of the protrusion 2 becomes the mold retainer 3 when the stator is molded.

  In the example of FIG. 1, the board holding component 40 includes three protrusion insertion holes 4 in the stator insulating portion into which protrusions (described later) of the stator insulating portion are inserted.

  In the example of FIG. 1, two claws 5 that are engaged with a substrate (described later) are provided.

  In the example of FIG. 1, two lead wire misalignment prevention protrusions 6 are provided that penetrate the substrate and prevent misalignment of lead wires (described later).

  In the example of FIG. 1, three positioning protrusions 7 for assembling with high accuracy on the substrate are provided.

  By connecting the nine protrusions 2 with the thin-walled connecting portion 40a, the material cost is minimized and the cost is reduced.

  As shown in FIG. 2, the substrate 11 has a substantially crescent shape, and a power supply wiring pattern is formed on the surface visible in FIG. Further, a position detection sensor (described later) is mounted on the rear surface, and a position detection circuit for a magnet of the electric motor is formed.

  The lead wire 10 is divided into a power lead wire 10a and a sensor circuit lead wire 10b in two stages, and is assembled to a lead wire lead-out component 9 that is exposed from the outer shell when the stator is molded, and is placed at a predetermined position. And are respectively soldered and joined to the substrate 11 at a power lead joint 15 and a sensor lead joint (described later) via a board-in connector 16. Here, an example in which the board-in type connector 16 is used is shown, but the lead wire 10 may be directly joined to the substrate 11.

  Since the lead wire 10 is divided into two stages of the power supply lead wire 10a and the sensor circuit lead wire 10b, it is not necessary to connect the patterns on both sides, so that a double-sided non-through substrate can be applied and the price is low. Become.

  At this time, if the lead wire 10a for power supply and the lead wire 10b for sensor circuit are arranged in the direction entering the lead wire lead-out component 9, the length of the lead wire 10 is shortest and the price is low. 10a and the sensor circuit lead wire 10b are joined to either one of the substrates 11 at a position where the other lead wire comes into contact with the other lead wire. It becomes high price.

  For this reason, the power supply lead wire joint portion 15 is disposed between the terminal joint portion 14a closest to the assembly portion of the lead wire lead-out component 9 of the substrate 11 and the next terminal joint portion 14b. Thereby, a wiring pattern (one) from the power lead wire joint 15 to the terminal joint 14a and a wiring pattern (two) from the power lead wire joint 15 to the terminal joint 14b and the terminal joint 14c are provided. And the three wiring patterns are not arranged in the width direction, the width of the substrate 11 can be reduced and the cost is reduced. In addition, it is easy to secure the wiring pattern width and the insulation distance between the wiring patterns.

  Moreover, the board | substrate 11 is equipped with the protrusion insertion hole 8 of the stator insulation part in which the protrusion (after-mentioned) of a stator insulation part is inserted in the example of FIG.

  In addition, the substrate 11 includes three positioning projection insertion holes 13 into which the positioning projections 7 of the substrate pressing component 40 are inserted and assembled with the substrate pressing component 40 with high accuracy in the example of FIG.

  In addition, the substrate 11 includes two lead wire misalignment prevention protrusion insertion holes 12 through which the lead wire misalignment prevention protrusions 6 of the substrate holding component 40 penetrate, as shown in FIG.

  The substrate 11 can flexibly cope with changes in specifications such as a change in the rotation direction of the electric motor by changing the wiring of the lead wires 10 and changing the position of the position detection sensor. Even when only power supply is required, the sensor circuit can be eliminated and a single-sided board can be used.

  As shown in FIG. 3, a position detection sensor 17 (an example of an electronic component) is mounted on the substrate 11. Then, the substrate holding component 40 is assembled to the substrate 11 to which the lead wire 10 is bonded. The positioning protrusion 7 of the substrate holding component 40 is inserted into the positioning protrusion insertion hole 13 of the substrate 11, and the substrate holding component 40. Since the claw 5 holds the substrate 11 from the inner diameter side of the substrate 11, the substrate 11 and the substrate pressing component 40 can be assembled with high accuracy without using an adhesive or the like. I am trying.

  Further, the lead wire misalignment prevention protrusion 6 of the board holding component 40 passes through the lead wire misalignment prevention protrusion insertion hole 12 of the substrate 11, so that the lead wire 10 passes the lead wire position misalignment prevention protrusion 6 to the inside. Prevents deviation.

  After the lead wire 10 is soldered to the substrate 11 and the substrate holding component 40 is assembled, the lead wire lead-out component 9 is assembled. At this time, the lead wire misalignment prevention protrusion 6 of the board pressing component 40 is effective in preventing misalignment of the power lead wire 10a. Further, it is possible to prevent the power supply lead wire 10a from moving to the position detection sensor 17 side due to the pressure at the time of molding the stator. The power supply lead wire 10 a is joined to the substrate 11 by the sensor lead wire coupling portion 18. The mold pressing surface 19 of the claw 5 of the substrate pressing component 40 will be described later.

  As shown in FIG. 4, in the stator 50, a stator core 23 is provided with a stator insulator 24, and concentrated winding coils 33 are wound around each of the 12 stator insulators 24a. It has been turned.

  In addition, the stator insulating portion 24 includes a terminal 20 to which power is supplied, a substrate installation surface 22, and a stator insulation portion protrusion 21 protruding in the axial direction from the substrate installation surface 22.

  As shown in FIG. 5, the stator 100 of the electric motor in which the substrate 11 with the substrate holding component 40 assembled is assembled to the stator 50, the protrusion 21 of the stator insulating portion is the portion of the stator insulating portion of the substrate 11. The board 11 is installed so as to be in contact with the board installation surface 22 of the stator insulation part 24 by being inserted into the projection insertion hole 8 and the projection insertion hole 4 of the stator insulation part of the board holding part 40, and the board holding part 40 is fixed. By fixing the protrusion 21 of the stator insulating portion protruding in the axial direction from the protrusion insertion hole 4 of the child insulating portion at the welded portion 1, the stator 50, the substrate pressing component 40, and the substrate 11 are fastened together. Has been fixed.

  At this time, the protrusions 2 of the board pressing component 40 are arranged on both sides of the terminal 20 of the stator 50. The protrusion 2 of the board holding component 40 protrudes in the axial direction from the terminal 20 of the stator 50. Therefore, quality is improved by reducing the pressure against peeling of the solder joint between the substrate 11 and the terminal 20 during molding by pressing the protrusions 2 provided on both sides of the terminal 20 with a mold.

  In addition, the substrate pressing component 40 and the substrate 11 are fixed without increasing the number of steps, so that the cost can be reduced.

  The stator 100 of the electric motor to which the substrate holding component 40 and the substrate 11 are attached is placed in a mold and molded into a mold stator (described later). When the resin is molded, the substrate holding component 40 The mold pressing portion 3 of the projection 2 and the mold pressing surface 19 of the claw 5 of the substrate pressing component 40 are sandwiched between the molds, whereby the substrate pressing component 40 is fixed to the mold, and the substrate pressing component 40 This prevents the substrate 11 fixed in the axial direction from being deformed.

  As shown in FIG. 6, the electric motor 200 includes an electric motor stator 100 to which the board holding component 40 and the board 11 are attached. The rotor 28 having two bearings 28b is inserted, and the bracket 42 is assembled and assembled.

  The manufacturing process of the electric motor 200 will be described with reference to FIG.

  The stator insulation 23 is applied to the stator core 23, and the concentrated winding type coil 33 is wound around each tooth 23a (S10).

  The substrate pressing component 40 is formed (S20).

  The substrate 11 is manufactured (S30).

  The power supply lead wire 10a and the sensor circuit lead wire 10b are joined to the substrate 11 using the board-in connector 16 (S40).

  The board holding component 40 is assembled to the board 11. The positioning protrusion 7 of the substrate pressing component 40 is inserted into the positioning protrusion insertion hole 13 of the substrate 11 (S50).

  The lead wire lead-out component 9 is assembled to the substrate 11 on which the substrate pressing component 40 is assembled (S60).

  The substrate 11 on which the substrate pressing component 40 is assembled is set on the stator 50. The protrusion 21 of the stator insulating portion is inserted into the protrusion insertion hole 8 of the stator insulating portion of the substrate 11 and the protrusion insertion hole 4 of the stator insulating portion of the substrate holding component 40 (S70).

  The protrusions 21 of the stator insulating portion are thermally welded by the welded portion 1 to fix the substrate 11 to the stator 50 (S80).

  The terminal 20 of the stator 50 and the board 11 are soldered to complete the stator 100 of the electric motor (S90).

  The stator 100 of the electric motor is set in a mold for resin molding. At this time, the mold pressing portion 3 of the protrusion 2 of the substrate pressing component 40 and the mold pressing surface 19 of the claw 5 of the substrate pressing component 40 are sandwiched between the molds and are resin-molded to form the mold stator 29 ( S100).

  The rotor 28 having the shaft 28a and the bearing 28b is inserted into the mold stator 29, and the bracket 42 is assembled to complete the electric motor 200 (S110).

  As described above, according to the first embodiment, in the mold stator 29 after molding, since the substrate 11 is not exposed to the outside, moisture hardly reaches the substrate 11 and quality can be improved. In addition, the cost can be reduced because the substrate 11 can be made small and a double-sided non-through substrate can be applied.

  When the stator 100 of the electric motor according to the first embodiment is applied to the electric motor 200, the quality of the electric motor 200 is improved along with the improvement of the quality of the stator 100 of the electric motor, and the price of the electric motor 200 is reduced by reducing the size of the substrate 11. Reduction is possible.

Embodiment 2. FIG.
FIG. 8 is a diagram showing the second embodiment, and is a perspective view showing a stator of an electric motor to which a board on which a drive circuit is mounted is assembled.

  The substantially circular substrate holding component 60 is assembled to the substantially circular substrate 27 on which the drive circuit is mounted, and is set on the same stator 50 as in the first embodiment. Then, the protrusion 21 of the stator insulating portion is thermally welded at the weld portion 1, and the substrate 27 on which the drive circuit is mounted is fixed to the stator 50 to form the stator 300 of the electric motor.

  A driving IC 25 (an integrated circuit, an example of an electronic component) is mounted on the substrate 27 on which the driving circuit is mounted. The function of the substrate pressing component 60 is the same as that of the first embodiment. However, in addition to the function shown in the first embodiment, the substrate pressing component 60 is used to prevent the IC 25 from floating when the stator 300 of the electric motor is molded. In addition, an IC floating prevention protrusion 26 (an example of an electronic part floating prevention protrusion) is added. By adding the IC floating prevention protrusion 26, it is possible to prevent the IC 25 from floating when molding the stator 300 of the electric motor, so that the quality can be further improved, and the electric motor using the stator 300 of the electric motor is also accompanied by the quality. Can be improved.

Embodiment 3 FIG.
FIG. 9 is a diagram illustrating the third embodiment, and is a configuration diagram of the air conditioner 400.

  The air conditioner 400 includes an indoor unit 30 and an outdoor unit 31. The outdoor unit 31 has a blower 32. The indoor unit 30 also includes a blower (not shown). The electric motor 200 of the first embodiment or the electric motor of the second embodiment is mounted on the blower 32 of the outdoor unit 31 and the blower of the indoor unit 30.

  By using the high-quality electric motor 200 of the first embodiment or the electric motor of the second embodiment for the blower 32 of the outdoor unit 31 and the blower of the indoor unit 30 that are main parts of the air conditioner 400, the air conditioner 400 is used. Quality improvement.

FIG. 4 is a diagram showing the first embodiment, and is a perspective view of a substrate pressing component 40. FIG. FIG. 5 shows the first embodiment and is a perspective view of a substrate 11. FIG. FIG. 5 is a diagram illustrating the first embodiment and is a diagram illustrating a back surface in which a substrate pressing component 40 is assembled to a substrate 11. FIG. 5 is a diagram showing the first embodiment, and is a perspective view of a stator 50. FIG. FIG. 3 is a diagram showing the first embodiment, and is a perspective view of a stator 100 of an electric motor in which a substrate 11 on which a substrate pressing component 40 is assembled is assembled to a stator 50. FIG. FIG. 5 shows the first embodiment and is a cross-sectional view of the electric motor 200. FIG. 5 shows the first embodiment, and shows a manufacturing process of the electric motor 200. FIG. It is a figure which shows Embodiment 2, and is a perspective view which shows the stator of the electric motor with which the board | substrate which mounted the drive circuit was assembled | attached. It is a figure which shows Embodiment 3, and is a block diagram of the air conditioner 400. FIG.

Explanation of symbols

  1 welding part, 2 protrusion, 3 mold holding part, 4 stator insulation part protrusion insertion hole, 5 claw, 6 lead wire misalignment prevention protrusion, 7 positioning protrusion, 8 stator insulation part protrusion insertion hole, 9 lead Wire lead-out component, 10 lead wire, 10a power supply lead wire, 10b sensor circuit lead wire, 11 substrate, 12 lead wire misalignment prevention projection insertion hole, 13 positioning projection insertion hole, 14a terminal joint portion, 14b terminal joint portion, 14c terminal joint, 15 power supply lead joint, 16 board-in type connector, 17 position detection sensor, 18 sensor lead wire joint, 19 mold holding surface, 20 terminals, 21 stator insulation projection, 22 substrate Installation surface, 23 Stator iron core, 23a teeth, 24 Stator insulation, 25 IC, 26 IC floating prevention protrusion, 27 Base mounted with drive circuit Plate, 28 Rotor, 28a Shaft, 28b Bearing, 29 Mold stator, 30 Indoor unit, 31 Outdoor unit, 32 Blower, 33 Coil, 40 Substrate holding part, 40a Thin connector, 42 Bracket, 50 Stator, 60 Substrate Presser parts, 100 electric motor stator, 200 electric motor, 300 electric motor stator, 400 air conditioner.

Claims (11)

In the stator of an electric motor to which a board on which electronic components are mounted is assembled,
A motor stator, comprising: a substrate pressing part that is assembled to the substrate and is pressed by a mold for molding when the stator of the motor is molded. In the stator of an electric motor to which a board on which electronic components are mounted is assembled,
A stator insulating part having a protrusion of the stator insulating part protruding in the axial direction;
A substrate holding part that is assembled to the substrate and has a protrusion extending in a direction perpendicular to the substrate in a state of being assembled to the substrate, and is fixed to the protrusion of the stator insulating portion together with the substrate; ,
A stator for an electric motor, wherein, at the time of molding the stator of the electric motor, the projection of the substrate pressing component is pressed by a mold for molding and molding is performed.   3. The stator of an electric motor according to claim 2, wherein the protrusions of the board pressing component that protrude in an axial direction from the terminal are located on both sides of the terminal provided in the stator insulating portion.   The board holding component has a claw for engaging the board on the side opposite to the projection, and sandwiches the projection and the claw with a mold for molding the stator of the electric motor. The stator for an electric motor according to claim 2. A positioning protrusion provided on the substrate pressing component and extending in a direction opposite to the protrusion;
The stator of the electric motor according to claim 2, further comprising a positioning protrusion insertion hole provided on the substrate and fitted into the positioning protrusion. A lead wire lead component assembled to the substrate;
Provided on the substrate, a power lead wire joint to which a power lead is joined,
A plurality of terminal joints provided on the substrate and to which the terminals of the stator insulation part are joined;
The power supply lead wire joint portion of the substrate is disposed between the terminal joint portion closest to the assembly portion of the lead wire lead-out component of the substrate and the terminal joint portion closest to the next. The stator of the electric motor according to claim 2. A power supply lead wire connected to a power supply lead wire joint provided on the substrate;
3. The stator for an electric motor according to claim 2, wherein a lead wire misalignment prevention protrusion is provided on the board pressing component so as to extend in a direction opposite to the protrusion and prevent the power lead wire from being misaligned.   2. The stator of an electric motor according to claim 1, wherein the board is provided with a driving circuit, and includes an electronic component lifting prevention protrusion for preventing the electronic component used in the driving circuit from floating. A mold stator obtained by resin-molding the stator of the electric motor according to any one of claims 1 to 8,
A rotor inserted into the mold stator and having a shaft and a bearing;
An electric motor comprising: a bracket assembled to the mold stator.   An air conditioner comprising the electric motor according to claim 9 mounted on a blower. In the manufacturing method of the electric motor in which the board on which the electronic component is mounted is assembled to the stator,
A process of manufacturing a stator by applying a stator insulation to the stator core and winding a coil;
A process of forming a substrate holding part;
A process of manufacturing a substrate;
Bonding a lead wire to the substrate;
Assembling the substrate pressing component to the substrate;
Assembling a lead wire lead-out component on the substrate;
Fixing the substrate on which the substrate pressing component is assembled to the stator, and manufacturing a stator of an electric motor;
Storing the stator of the electric motor in a mold, and forming a mold stator by resin molding by sandwiching the substrate pressing part between the molds; and
And a step of manufacturing a motor by inserting a rotor into the mold stator and assembling a bracket.

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