JP3679305B2

JP3679305B2 - Refrigerant compressor

Info

Publication number: JP3679305B2
Application number: JP2000082829A
Authority: JP
Inventors: 聡小山; 昌一郎北市
Original assignee: Toshiba Carrier Corp
Current assignee: Toshiba Carrier Corp
Priority date: 2000-03-23
Filing date: 2000-03-23
Publication date: 2005-08-03
Anticipated expiration: 2020-03-23
Also published as: JP2001268835A

Description

【０００１】
【発明の属する技術分野】
本発明は、たとえば冷凍機や空気調和機の冷凍サイクルを構成する冷媒圧縮機に係わり、特に、電動機部の巻線に対する絶縁部材に関する。
【０００２】
【従来の技術】
たとえば冷凍機や空気調和機に用いられる圧縮機は、冷媒を圧縮する圧縮機構部と、この圧縮機構部を駆動する固定子と回転子を備えた電動機部とから構成される。
【０００３】
上記電動機部において、冷凍サイクル運転の省エネルギおよび快適性を追求すべく、２極あるいは４極三相の巻線が施され、インバータ電源で駆動されるものが多用される傾向にある。
【０００４】
たとえば、特開平１０−２８８１８０号公報においては、冷媒圧縮機の電動機部についての技術が開示されている。ここでは、電動機部を構成する固定子として、固定子鉄心を構成するティース部に絶縁部材（コイルボビンとも呼ばれる）を嵌め込み、この絶縁部材を介してティース部に巻線を施す、いわゆる集中巻きと呼ばれる方式が採用されている。
【０００５】
一方、特願平１１−２２７５３９号には、絶縁部材をモールドする際の樹脂注入口（ゲート）の位置と数量、樹脂モールド素材の選択および具体的な材料特性、内側鍔部と巻き胴部との交差するコーナー部のＲ形状、適用される冷媒と冷凍機油の組み合せなどの技術が開示されている。
【０００６】
すなわち、上記絶縁部材は、断面矩形状のティース部に嵌め込まれる矩形枠体からなる胴部と、この胴部の内周縁と外周縁とに沿って一体的に設けられる内側鍔部および外側鍔部とからなる。
【０００７】
このような絶縁部材をモールド成形するのにあたって、樹脂注入口を備えたモールド金型は、固定側金型に内側鍔部と外側鍔部が構成され、可動側金型に胴部のティース絶縁部が掘り込まれて、内外鍔部と胴部を構成する巻き胴部とティース絶縁部が一体形成される。
【０００８】
このため、個々の製品形状に対応した絶縁部材をモールド成形するための金型が用いられ、固定側金型と可動側金型との分割面（パーティング面）は、巻き胴部とティース絶縁部が交差する近傍に構成されている。
【０００９】
【発明が解決しようとする課題】
しかしながら、絶縁部材の胴部の巻き胴部とティース絶縁部が交差するコーナー部において、巻線が巻回される際の張力で絶縁部材と巻線が強く接触してしまい、巻線絶縁被膜の損傷や、巻線の押圧による絶縁部材の損傷（圧縮窪み）などが生じ易い。そして、このため巻線の絶縁不良や、着磁工程時にかかる大きな力により絶縁部材の損傷箇所を起点とする内側鍔部の折損があった。
【００１０】
また、絶縁部材のティース絶縁部は薄肉のためにモールド金型からの取り出し（離型）が困難で、上記巻き胴部とティース絶縁部が交差するコーナー部でのクラック発生により、絶縁部材の絶縁不良があった。さらに、固定側金型と可動側金型との合せ面（パーティング面）の隙間で生じたバリによって、巻線の絶縁被膜を損傷する問題があった。
【００１１】
また、固定子鉄心と回転子の厚みだけを変更した電動機部においても、一体形の絶縁部材はティース絶縁部の長さが決まっていて、同一形状寸法の絶縁部材をそのまま用いることができなかった。
【００１２】
本発明は、上記事情を考慮してなされたものであり、その目的とするところは、高い信頼性と生産性に優れる電動機を備えた冷媒圧縮機を提供しようとするものである。
【００１３】
【課題を解決するための手段】
上記目的を満足するため本発明の冷媒圧縮機は、冷媒を圧縮して吐出する圧縮機構部と、この圧縮機構部を駆動する固定子および回転子とから構成される電動機部を備えた冷媒圧縮機において、上記固定子は、円環状継鉄であるヨーク部に一体に複数個のティース部を放射状に設置し、各々のティース部に絶縁部材を介して巻線を巻装してなり、上記絶縁部材は、樹脂モールド成形品であり、内側鍔部と外側鍔部、およびこれら内，外側鍔部を連結し巻線が巻装される胴部とから構成され，上記胴部のコーナー部に、上記巻線の線径の１／２以上かつ４倍以下の半径のＲ面取りを設けたことを特徴とする。
【００２２】
以上のごとき課題を解決する手段を採用することにより、巻線の絶縁被膜と絶縁部材の損傷が改善され、絶縁不良や着磁した際の絶縁部材の折損を防止でき、固定子鉄心厚みの異なる製品にも同一形状の絶縁部材を採用できて生産性が向上し、信頼性の向上に繋げられる。
【００２３】
【発明の実施の形態】
以下、図面を参照して本発明の実施の形態について説明する。
【００２４】
図１に示す、１は密閉形の冷媒圧縮機であり、２はアキュムレータである。冷媒圧縮機１は、密閉ケース３内の下部に圧縮機構部４が設けられ、上部には電動機部５が設けられる。これら圧縮機構部４と電動機部５とは回転軸６を介して連結される。
【００２５】
上記電動機部５は、密閉ケース３の内面に固定された固定子８と、この固定子８の内側に所定の隙間を介して配置され、かつ上記回転軸６が介挿される回転子９とから構成される。
【００２６】
上記圧縮機構部４は、回転軸６の下部に仕切り板１０を介して上下に配設された２つのシリンダ１１Ａ，１１Ｂを備えている。上部シリンダ１１Ａは、その上面部が主軸受１２に取付固定される。下部シリンダ１１Ｂの下面部には副軸受１３が取付固定される。
【００２７】
シリンダ１１Ａ，１１Ｂの上下面は、上記仕切り板１０および主軸受１２と副軸受１３で区画され、その内部にシリンダ室１５ａ，１５ｂが形成される。それぞれのシリンダ室１５ａ，１５ｂには、回転軸６の回転にともなってローラを偏心回転駆動するとともに、ベーンによってシリンダ室を高圧側と低圧側に仕切る、いわゆるロータリ式圧縮機構１６Ａ，１６Ｂが構成される。両シリンダ１１Ａ，１１Ｂ内のシリンダ室１５ａ，１５ｂは、それぞれ導通管１７ａ，１７ｂを介して上記アキュームレータ２に連通される。
【００２８】
一方、上記密閉ケース３の上面部には吐出冷媒管１９が接続され、図示しない凝縮器に連通される。上記アキュームレータ２の上面部には吸込み冷媒管２１が接続され、図示しない蒸発器に連通される。上記凝縮器と上記蒸発器との間には膨張機構が接続されていて、冷媒圧縮機１−凝縮器−膨張機構−蒸発器を介して上記アキュームレータ２に順次連通する冷凍サイクルが構成される。
【００２９】
図２（ａ）（ｂ）は、上記電動機部５の平面視と正面視の図であり、固定子８の内側に回転子９が配置される。上記固定子８は、円環状継鉄であるヨーク部３２と、このヨーク部の内側に所定間隔を存して放射状に設置される複数（６個）のティース部３３とから構成され、鋼板を積層してなる固定子鉄心３０備えている。
【００３０】
上記ティース部３３は、後述するように絶縁部材４０で覆われていて、この絶縁部材を介して巻線３１が施されている。なお、図２（ａ）において絶縁部材４０を省略して巻線３１を示し、図２（ｂ）において固定子鉄心３０の上下端面から絶縁部材４０の一部が突出する状態を示す。
【００３１】
上記固定子８におけるスロット（ティース部３３）の数を６個とし、かつ上記回転子９の極数を４極に設定するよう、固定子鉄心３０に対する巻線３１が施されている。
【００３２】
上記回転子９は、ヨーク部３５と、このヨーク部３５内に埋設される複数（４個）の永久磁石３６からなる。上記永久磁石３６は無着磁の状態で組み立てられ、電動機部５として組み立てられたあと着磁化される。
【００３３】
図３に、６個のティース部３３に対し、それぞれの上部側と下部側から嵌め込まれる単体タイプの絶縁部材４０Ａを示していて、これら絶縁部材は全部で１２個用意される。
【００３４】
上記絶縁部材４０Ａは、内側鍔部Ａと外側鍔部Ｂおよび、これら内外側鍔部Ａ，Ｂ相互を連結する胴部Ｃとから構成される。特に、胴部Ｃを断面にした状態でほぼコ字状に形成されていて、組み立てられたとき上記ティース部３３の端面に密接する部分を巻き胴部ｃと呼び、この巻き胴部の両端に一体に設けられ上記ティース部３３の両側面に沿う一対の面をティース絶縁部ｄ，ｄと呼び、ｆはこれらティース絶縁部ｄの先端である。
【００３５】
同図の、▲１▼〜▲４▼の×印は、絶縁部材４０をモールド成形する際の樹脂注入口であるゲートの位置を示していて、上記内側鍔部Ａと外側鍔部Ｂとの少なくともいずれか一方に対向して設けられる。
【００３６】
また、図４に示すような絶縁部材４０Ｂであってもよい。この絶縁部材４０Ｂの場合は、６個全てのティース部３３に亘って、かつ上部側から嵌め込まれる上部側絶縁部材４０Ｂａと下部側から嵌め込まれる下部側絶縁部材４０Ｂｂとからなる全体タイプであって、したがって２個あればよい。
【００３７】
図５（ａ）は、全体タイプの絶縁部材４０Ｂを構成する、上記ティース部３３の上部側から嵌め込まれる上部側絶縁部材４０Ｂａの平面視を示し、同図（ｂ）に同図（ａ）のｂ−ｂ断面を示す。
【００３８】
図６（ａ）は、全体タイプの絶縁部材４０Ｂを構成する、上記ティース部３３の下部側から嵌め込まれる下部側絶縁部材４０Ｂｂの平面視を示し、同図（ｂ）に同図（ａ）のｂ−ｂ断面を示す。図７は、全体タイプの絶縁部材４０Ｂであって、そのうちの上部側絶縁部材４０Ｂａの斜視図である。
【００３９】
上，下部側絶縁部材４０Ｂａ，４０Ｂｂは、図５（ａ）、図６（ａ）および図７に示すように、内側鍔部Ａと外側鍔部Ｂおよび、これら内外側鍔部Ａ，Ｂ相互を連結する胴部Ｃとから構成される。
【００４０】
特に、図５（ｂ）、図６（ｂ）に示すように、上記胴部Ｃを断面にした状態で、上記ティース部３３の一端面に密接する面を巻き胴部ｃと呼び、ティース部の両側面に沿う対向する面をティース絶縁部ｄと呼び、ｆはティース絶縁部ｄの先端をなす。
【００４１】
先に説明した絶縁部材４０（詳しくは、４０Ａ，４０Ｂ以下同）において、詳細は図５（ｂ）と図６（ｂ）に示すように、巻き胴部ｃとティース絶縁部ｄの境目をなすコーナー部４１に、上記巻線３１の線径の１／２以上のＲ面取りを設けたことを特徴としている。
【００４２】
以上の絶縁部材４０の効果を確認するために、コーナー部４１のＲ面取りの大きさを種々変えた絶縁部材に巻線を施し、この巻線の絶縁被膜の損傷程度と、巻線断面の変形状態と、コーナー部における窪み変形、および着磁後の内側鍔部Ａの折損状態などを評価した。
【００４３】
具体的に、絶縁部材４０を固定子鉄心３０を構成するティース部３３に嵌め込んだうえで巻線３１を巻回する巻線作業は、一定のテンションと巻速度を設定して行われる。このとき、絶縁部材４０の内側鍔部Ａにかかる荷重は５０〜１００ｋｇｆである。
【００４４】
また、絶縁部材４０Ａ，４０Ｂの素材として、ＰＰＳ樹脂（ポリフェニレンサルファイド）材が選択されている。
【００４５】
巻線３１の線径はφ１．０ｍｍであり、図８（ｂ）に示すように、コーナー部４１のＲ面取りを、Ｒ：０．１、Ｒ：０．３、Ｒ：０．５、Ｒ：１．０、Ｒ：２．０（ｍｍ）の５種類で実施した。
【００４６】
図９（ａ）〜（ｄ）は、上記条件で得られた評価の詳細を説明している。すなわち、図９（ａ）において、巻線後の巻線３１を被覆する絶縁被膜４２の破損態観察をなした。図９（ｂ）において、巻線後の巻線３１の、はじめの線径に対する変形量を測定した。図９（ｃ）において、絶縁部材４０のコーナー部４１の窪み量を測定し、同図（ｇ）に図９（ｃ）のｇ−ｇ断面を示す。図９（ｄ）において、着磁後の内側鍔部Ａ根元でのクラック有無を確認した。
【００４７】
以上の４項目での評価を実施し、以下の表１に、評価結果をまとめた。なお、巻線後の巻線変形と、コーナー部４１の窪みは、表１の▲３▼Ｒ：０．５（ｍｍ）の仕様を１．０としたときの相対値で示している。
【００４８】
【表１】

【００４９】
以上の結果から、▲３▼から▲５▼の仕様によれば、巻線３１表面の絶縁被膜４２の破損が無く、巻線３１と絶縁部材４０の変形が小さくてすむ。また、着磁後の内側鍔部Ａの根元にクラック発生が無いことが分かった。
【００５０】
一方、▲１▼と▲２▼の仕様によれば、Ｒ面取り寸法が小さいために、上記コーナー部４１で応力集中を受け、絶縁被膜４２の破損と、巻線３１の変形があり、かつコーナー部４１での窪みが大となる。さらに、着磁の際に内側鍔部Ａが回転子９側に倒れようとする力に対して窪み部に応力集中し、この窪みが起点となってクラックが発生することが分かった。
【００５１】
つまり、Ｒ面取りを線径の１／２（０．５部）以上に設定することによって、巻線時の応力集中を緩和して、信頼性を高められる。ただし、必要以上にＲ面取りを大きくすると、コーナー部４１の厚みが薄くなり、絶縁部材４０の強度低下を招くため、Ｒ面取りは線径の１／２から４倍の範囲が好ましい。
【００５２】
図１０に示すような構成であってもよい。
ここでは、絶縁部材４０を構成する胴部Ｃにおける巻き胴部ｃの表面が緩やかな凸面状をなす凸部４４に形成されている。上記凸部４４は、巻線３１を巻回する際に接触する高さ（凸高さ）を有している。
【００５３】
先に図８（ａ）に示すように、通常構成では、巻き胴部ｃと巻線３１との間に巻線隙間４３ができて、そのためコーナー部４１に応力が集中してしまう。ところが、図１０に示す凸部４４を形成することによって、凸部が巻線３１の張力の一部を受け、先に説明したような巻線隙間が生じることがない。したがって、コーナー部４１に対する巻線３１の接触力が緩和し、かつ巻線の絶縁被覆４２の損傷を防止し、コーナー部４１の窪みを防止できる。
【００５４】
上記凸部４４は、巻き胴部ｃの両側コーナー部４１相互間の距離と、コーナー部４１のＲ形状や、巻線３１の線径および弾性力と、巻線３１の張力などの諸条件によって設定されるが、巻線３１と絶縁部材４０の接触長さが長いほど効果が大きい。
【００５５】
なお、凸部４４の断面形状として、図１０に示すような全面に亘って緩やかな円弧状が好ましいが、これに限定されるものではなく、図１１（ａ）に示すような中央部のみの凸部４４ａであってもよく、逆に、図１１（ｂ）に示すように中央部を凹陥形成し、その両側を凸部４４ｂとしても、同様の効果が得られる。
【００５６】
また、図１２および図１３に示すように、ここでは、図１２に示すように、ティース絶縁部ｄの先端ｆで、かつこの先端の基部側の厚みＴ１と、上記コーナー部４１の厚みＴ２との関係を、Ｔ１＞Ｔ２に設定した。
【００５７】
以上の寸法設定をなしたうえで、図１３に示すように、上部側絶縁部材４０Ｂａと下部側絶縁部材４０Ｂｂを嵌め込む。これら絶縁部材の先端ｆ相互を重ね合わせた重ね代ｆが互いに接触することによって、重ね代同士が押さえ付けられ、この重ね代ｆ間の隙間を埋めることから、絶縁特性が向上する。
【００５８】
先に説明したＴ１＞Ｔ２の関係によって、特にＴ１が巻線３１を巻回したときの接触厚みとなる。すなわち、この厚みＴ１を有することによって、巻線３１の張力の一部を受け、コーナー部４１に対する巻線の接触力を緩和して、上述した凸部４４と同様の効果が得られる。なお、巻き胴部ｃの断面形状として、上記凸部４４と同じ緩やかな円弧状の面とすれば、さらに有効となる。
【００５９】
さらに、図１２および図１３に示す構成であってもよい。すなわち、先に、図１０でも説明したように巻き胴部ｃの凸部４４の厚さＴｃと、ティース絶縁部ｄの先端ｆ基端側厚みＴ１の関係が、Ｔｃ＞Ｔ１に設定される。
【００６０】
これは、上部側絶縁部材４０Ｂａと下部側絶縁部材４０Ｂｂとのコーナー部４１相互間の距離が巻き胴部ｃの両側コーナー部４１相互間の距離より長いことから、Ｔ１が小さくても巻線３１は十分に接触できる。
【００６１】
一方、巻き胴部ｃの厚みＴｃは、絶縁部材コーナー部４１のＲ面取りを大きく取るためと、上記コーナー部４１間の距離が短いために凸部４４の高さを高くすることが必要なことから、Ｔｃは厚くなければならない。そのため、Ｔｃ＞Ｔ１の設定によって、さらに効果が発揮される。
【００６２】
なお、再び図１および図２（ａ）に示すように、上記電動機部５としての直流モーターでは、回転子９の永久磁石３６に対して組立て時に着磁の必要がある。ただし、この着磁の際に、着磁電流が固定子８の巻線３１に流れて、巻線３１の電磁力により絶縁部材４０の鍔部に変形が生じことがある。
【００６３】
このとき、絶縁部材４０に形成される窪みが起点となってクラックが発生していたが、表１の結果に示すように、上述の特性を備えた絶縁部材４０を採用することにより、電磁力による割れを防止して良好な結果を得た。
【００６４】
さらに、別の手段を、図１４（ａ）〜（ｃ）と、図１５（ａ）（ｂ）に示している。
はじめに、図１５から説明すると、同図（ａ）は射出成形加工の概略構成であり、射出成形加工機６０と、モールド金型４６と、モールド金型を構成する可動側金型４７および固定側金型４８と、各金型４７，４８の分割面４９（パーティング面）などを示している。同図（ｂ）は、上記モールド金型４６のみを拡大して示している。
【００６５】
上記射出成形加工機６０による射出成形加工から説明すると、射出成形加工機６０に接続されるホッパー６３へ樹脂素材を投入する。加工機のシリンダ６１内ではスクリュー６２が回転し、ホッパー６３に投入した樹脂素材を先端側へ送る。この途中で、シリンダ６１の肉厚内に埋設されるヒーターＨにより、投入された樹脂素材が加熱溶融される。上記スクリュー６２の回転後退で溶融した弗素樹脂が先端側に溜められ、かつスクリュー６２の直進で溶融弗素樹脂がモールド金型４６へ注入される。
【００６６】
モールド金型４６においては、溶融樹脂が冷やされ固化する温度に設定されている。加工機６０からモールド金型４６を構成する固定側金型４８の注入路５３を介して注入された溶融樹脂は、ゲートである注入口５４からキャビティ内に導かれ、ここで集溜し、かつ所定の時間設定にもとづいて冷却固化して絶縁部材４０が成形されることとなる。なお、上記ゲートである注入口５４の位置は、胴部Ｃのうちの内側鍔部Ａもしくは外側鍔部Ｂの、少なくともいずれか一方に設けている。
【００６７】
キャビティ内で溶融樹脂が冷却され固化したタイミングをとって可動側金型４７が後退駆動され、分割面４９の位置で可動側金型４７と固定側金型４８が分割される。その際、注入口５４は成形された絶縁部材４０と切り離される。
【００６８】
可動側金型４７に残った絶縁部材４０に対して、突き出しプレート５２が前進し、ここに設けられる突き出しピン５０が絶縁部材４０を押し出してモールド金型４６から取り出す。
【００６９】
さらに説明すると、同図（ｂ）に示すように、上記固定側金型４８は第１の分割金型４８ａと第２の分割金型４８ｂとに分割化されていて、これら分割金型４８ａ，４８ｂを互いに開くことによって上記注入路５３を取り出せる。
【００７０】
そして、これら分割金型４８ａ，４８ｂから上記絶縁部材４０と注入路５３にある冷却固化した樹脂を取り除いたあとに、可動側金型４７と固定側金型４８を閉じ、再度同じ工程を繰り返すこととなる。
【００７１】
図１４（ａ）〜（ｃ）は、ティース絶縁部ｄを構成する部分の金型分割面４９の状態を示す一部断面図である。ティース絶縁部ｄの先端ｅに相当する位置に分割面４９が設けられている。
【００７２】
ティース絶縁部ｄの厚み方向の形状として、図１４（ｂ）に示される固定側金型４８と可動側金型４７の分割と、図１４（ｃ）に示される絶縁部材４０の取り出しに必要な傾斜（テーパー）が設けられる。したがって、このティース絶縁部ｄの厚みは、巻き胴部ｃ＜先端ｅの関係であり、このような分割面４９を設けることによって、絶縁部材４０が金型から取り出される際の抵抗が減少してクラックの発生を防止できる。
【００７３】
具体的には、上記固定子鉄心３０は磁性鋼板の積層で構成されるために、ティース部３３のコーナーに面取り等の加工ができず、このコーナーに位置する絶縁部材４０のコーナー部４１もまた大きな面取りを施すことかできない。モールド成形した絶縁部材４０を金型から取り出す際の抵抗が大きいと、上記コーナー部４１に集中応力が発生してクラックの要因となる。
【００７４】
しかしながら、ここでは上記した分割面４９の存在によって、可動側金型４７が開くと同時にティース絶縁部ｄの片面が開放される。そして、可動側金型４７に残った絶縁部材４０を突き出しピン５０で押し上げて取出すようになっているために、可動側金型４７と絶縁部材４０の摩擦抵抗が大幅に低減し、コーナー部４１への負荷が減少してクラック発生を防止する。
【００７５】
さらにまた、分割面４９に生じるバリ５１が、巻線３０がストレスを最も受けるコーナー部４１から離れた位置に形成されることから、製造過程でたとえバリ５１が残ったとしても巻線３０に対するストレスは小さく、絶縁被膜４２の損傷などの不良発生を防止できる。
【００７６】
なお、バリの除去処理について言うならば、バリ５１が先端ｅに発生するために、ティース絶縁部ｄ内などの奥まった位置に生じるバリに比較すれば、バリ取り処理が容易である。また、この金型構成により請求項３のティース絶縁部ｄの厚みＴ１＞Ｔ２の関係が容易に形成できる。
【００７７】
上述の分割面４９は、絶縁部材４０ティース絶縁部ｄの先端ｅに近ければ近いほど効果は大きい。最先端に分割面４９を設けることが望ましいが、図１３に示される上，下部側から嵌め込まれる上下部絶縁部材４０Ｂａ，４０Ｂｂには重ね代ｆの形成が必要であり、この重ね代ｆの形状によっては金型構成上困難になる場合もある。
【００７８】
比較例としての金型構成を、図１６に示す。すなわち、以下のような金型構成も考えられる。
こでは分割面４９がコーナー部４１近傍に設けられ、ティース絶縁部ｄが全て可動側金型４７に形成されている。したがって、絶縁部材４０を可動側金型４７から取出すのに必要な傾斜を設けるためにティース絶縁部ｄの厚みは、巻き胴部ｃ＜先端ｅ（Ｔ１＜Ｔ２）の関係となってしまう。
【００７９】
また、固定子鉄心３０と巻線３１の絶縁距離を大きく取れないために、この厚みは小さく、かつ傾斜も小さくする必要がある。そのため、絶縁部材４０が可動側金型４７から取出される際の抵抗が大きく、コーナー部にクラックが生じる虞れがある。
【００８０】
また、図１７に示すように、図１４（ａ）〜（ｃ）で説明した金型構成を前提として、固定側金型４８で形成される絶縁部材表面粗さ４６ａと、可動側金型４７で形成される絶縁部材表面粗さ４６ｂの関係を、４４ａ＜４４ｂとなるように設定している。
【００８１】
基本的に、絶縁部材４０の表面粗さは金型表面粗さが転写されるために、金型の表面粗さで決定される。具体的には、固定側金型４８の表面粗さを小に設定すれば、絶縁部材４０の表面粗さ４６ａが小さくなる。
【００８２】
このような設定から、固定側金型４８と可動側金型４７との金型開きの際に、固定側金型４８に対する絶縁部材４０の摩擦抵抗が小さくなり、絶縁部材４０へのストレスが減少する。コーナー部４１への負荷が減少してクラック発生を防止する。絶縁部材の表面粗さ４６ａが小さい面に巻線３１が巻回されるので、巻線絶縁被膜４２の損傷を防止する効果もある。
【００８３】
さらに、図１８（ａ）（ｂ）に示すように、上部側と下部側から嵌め込まれる絶縁部材４０Ｂａ，４０Ｂｂ相互の先端部において、重ね代ｆの重なり合う距離５５を、図１８（ａ）では２ｍｍとし、図１８（ｂ）では１０ｍｍとしている。
【００８４】
上記固定子鉄心３０は、磁性鋼板を積層して構成されるために、厚み方向に製造バラツキが生じ易い。そのため、上述の重ね代ｆは製造バラツキの寸法公差と重なり合う距離５５を加味した長さ５６として設定される。
【００８５】
ここで、先に説明したようにティース絶縁部ｄの厚みＴ１，Ｔ２の関係を、Ｔ１＞Ｔ２とし、重ね代ｆを巻線３１で押さえ込むことから、図１８（ａ）で示すような距離２ｍｍであっても所定の絶縁特性が得られた。
【００８６】
また、重ね代ｆの厚みを大きく取ることが可能となり、樹脂が流れ易くなることから、図１８（ｂ）に示すように、距離５５を１０ｍｍまで延ばしても成形加工が可能である。よって、重ね代ｆの重なり合う距離５５は、絶縁特性と成形加工性とのバランスから、２ｍｍ〜１０ｍｍの範囲までとするとよい。
【００８７】
なお、先に図１６で説明した比較例としての金型構成において、ティース絶縁部厚みの関係がＴ１＜Ｔ２の場合は、重ね代と巻線に隙間が生じ絶縁特性が低下するため、距離を４ｍｍに設定する必要があった。
【００８８】
また、重ね代の厚みが小さくなることから樹脂が流れず、距離は成形加工上から６ｍｍが限界である。つまり、絶縁特性の面からは距離を長く確保したいが、成形加工上では距離に制限があり、固定子鉄心の製造バラツキを極力押さえる必要があった。
【００８９】
よって、上述の実施の形態のように、距離５５を２〜１０ｍｍの範囲で構成することにより、固定子鉄心３０の製造バラツキが大きくても対応でき、製造性が向上した。
【００９０】
また、図１９に示すようにしてもよい。
【００９１】
すなわち、上部側と下部側から嵌め込まれるような絶縁部材４０Ｂ_ａ１，４０Ｂ_ｂ１と合致する重ね代ｆを有する別体の中間絶縁部材５７を設けている。この中間絶縁部材５７は、ティース挿入部ｄと同形状の断面を有し、上下部側絶縁部材４０Ｂ_ａ１，４０Ｂ_ｂ１が重なり合う、重ね代ｆが形成されている。これらの間に中間絶縁部材５７を介在することによって、固定子鉄心３３の厚みが増しても、新らたにモールド金型を用意する必要がなく、絶縁部材４０Ｂをそのまま使用することができる。
【００９２】
これら電動機部５は、圧縮機構部４の効率向上をなし、トルク不足を固定子鉄心３３の厚みで補う。このため、中間絶縁部材５７を設けることで、絶縁部材４０Ｂの使用範囲が広がり製造性に優れる。
【００９３】
【発明の効果】
上記説明したように本発明によれば、巻線の絶縁被膜と絶縁部材の損傷が改善され、絶縁不良や着磁した際の絶縁部材の折損を防止でき、固定子鉄心厚みの異なる製品にも同一形状の絶縁部材を採用できて生産性が向上し、信頼性の向上に繋げられるなどの効果を奏する。
【図面の簡単な説明】
【図１】本発明の一実施の形態を示す、冷媒圧縮機の断面。
【図２】同実施の形態の、電動機部の平面図と正面図。
【図３】同実施の形態の、分割タイプの絶縁部材の正面図。
【図４】同実施の形態の、異なる仕様の絶縁部材およびゲート位置を示す図。
【図５】同実施の形態の、全体タイプで上部側絶縁部材の平面図と部分断面図。
【図６】同実施の形態の、全体タイプで下部側絶縁部材の平面図と部分断面図。
【図７】同実施の形態の、全体タイプで上部側絶縁部材の斜視図。
【図８】同実施の形態の、ティース部に嵌め込まれるティース絶縁部の一部断面図と、コーナー部のＲを説明する面。
【図９】同実施の形態の、破損状態を説明する斜視図と、正面図および部分断面図。
【図１０】同実施の形態の、絶縁部材の凸部を示す部分断面図。
【図１１】同実施の形態の、絶縁部材の他の変形例の凸部を示す部分断面図。
【図１２】同実施の形態の、絶縁部材のティース絶縁部厚みを示す部分断面図。
【図１３】同実施の形態の、上下部絶縁部材を互いに嵌め込んだ状態での、ティース絶縁部厚みを示す部分断面図。
【図１４】同実施の形態の、モールド金型構成と、モールド成形時における動作を示す部分断面図。
【図１５】同実施の形態の、射出成形加工機とモールド金型を示す断面図と、モールド金型の断面図。
【図１６】比較例としての、モールド金型構成と、モールド成形時における動作を示す部分断面図。
【図１７】同実施の形態の、モールド金型と絶縁部材の表面状態を説明する部分断面図。
【図１８】同実施の形態の、絶縁部材の上下部側の重なりを示す部分断面図。
【図１９】同実施の形態の、別体の絶縁部材の構成を示す部分断面図。
【符号の説明】
４…圧縮機構部、
８…固定子、
９…回転子、
５…電動機部、
３２…ヨーク部、
３３…ティース部、
３０…固定子鉄心、
４０…絶縁部材、
４０Ａ…絶縁部材、
４０Ｂ…絶縁部材、
３１…巻線、
Ａ…内側鍔部、
Ｂ…外側鍔部、
Ｃ…胴部、
ｃ…巻き胴部、
ｄ…ティース絶縁部、
４１…コーナー部、
４４…凸部、
４７…可動側金型、
４８…固定側金型、
５７…中間絶縁部材。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a refrigerant compressor constituting a refrigeration cycle of a refrigerator or an air conditioner, for example, and particularly relates to an insulating member for a winding of an electric motor unit.
[0002]
[Prior art]
For example, a compressor used in a refrigerator or an air conditioner includes a compression mechanism unit that compresses refrigerant, and an electric motor unit that includes a stator and a rotor that drive the compression mechanism unit.
[0003]
In the electric motor section, in order to pursue energy saving and comfort in refrigeration cycle operation, two-pole or four-pole three-phase windings are used, and those driven by an inverter power supply tend to be used frequently.
[0004]
For example, Japanese Patent Laid-Open No. 10-288180 discloses a technique regarding an electric motor part of a refrigerant compressor. Here, as a stator that constitutes the motor part, an insulating member (also called a coil bobbin) is fitted into a tooth part that constitutes the stator core, and winding is applied to the tooth part via this insulating member, so-called concentrated winding. The method is adopted.
[0005]
On the other hand, in Japanese Patent Application No. 11-227539, the position and quantity of a resin injection port (gate) when molding an insulating member, selection of resin mold material and specific material characteristics, an inner collar part and a winding drum part Techniques such as the R shape of the corner portion where the two intersect and the combination of the applied refrigerant and refrigerating machine oil are disclosed.
[0006]
That is, the insulating member includes a trunk portion made of a rectangular frame fitted into a teeth portion having a rectangular cross section, and an inner flange portion and an outer flange portion that are integrally provided along the inner and outer peripheral edges of the barrel portion. It consists of.
[0007]
When molding such an insulating member, a mold having a resin inlet has an inner flange portion and an outer flange portion formed on the fixed mold, and the teeth insulating portion of the trunk portion on the movable mold. Is engraved to integrally form a winding drum portion and a tooth insulating portion constituting the inner and outer flange portions and the trunk portion.
[0008]
For this reason, a mold for molding an insulating member corresponding to each product shape is used, and the dividing surface (parting surface) between the fixed mold and the movable mold is insulated from the winding drum section and the teeth. It is constructed in the vicinity where the parts intersect.
[0009]
[Problems to be solved by the invention]
However, at the corner portion where the winding body portion of the body portion of the insulating member intersects with the tooth insulation portion, the insulation member and the winding wire strongly contact with each other due to the tension when the winding wire is wound, and the winding insulation film Damage or damage (compression dent) of the insulating member due to the pressing of the winding is likely to occur. For this reason, there was a breakage of the inner flange portion starting from the damaged portion of the insulating member due to a poor insulation of the winding or a large force applied during the magnetization process.
[0010]
In addition, since the teeth insulating portion of the insulating member is thin, it is difficult to take out (release) it from the mold, and the insulation of the insulating member is caused by the occurrence of cracks at the corner where the winding drum portion and the teeth insulating portion intersect. There was a defect. Furthermore, there is a problem that the insulating coating of the winding is damaged by burrs generated in the gap between the mating surfaces (parting surfaces) of the fixed side mold and the movable side mold.
[0011]
In addition, even in an electric motor portion in which only the thickness of the stator core and the rotor is changed, the length of the teeth insulating portion is determined for the integral insulating member, and the insulating member having the same shape and dimension cannot be used as it is. .
[0012]
The present invention has been made in consideration of the above circumstances, and an object of the present invention is to provide a refrigerant compressor including an electric motor having high reliability and excellent productivity.
[0013]
[Means for Solving the Problems]
In order to satisfy the above object, the present inventionRefrigerant compressor compresses refrigerantIn the refrigerant compressor provided with an electric motor unit composed of a compression mechanism unit that discharges and a stator and a rotor that drive the compression mechanism unit, the stator is attached to a yoke unit that is an annular yoke. A plurality of teeth portions are integrally installed in a radial pattern, and windings are wound around each tooth portion via an insulating member. The insulating member is a resin molded product, and includes an inner flange portion and an outer flange portion. And a body part that connects the inner and outer flanges and is wound with a winding.The corner of the trunk has a radius that is not less than 1/2 and not more than 4 times the wire diameter of the winding.An R chamfer is provided.
[0022]
By adopting the means to solve the above problems, damage to the insulating film of the winding and the insulating member is improved, insulation failure and breakage of the insulating member when magnetized can be prevented, and the stator core thickness is different. Insulating members with the same shape can also be used for products, improving productivity and improving reliability.
[0023]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the drawings.
[0024]
In FIG. 1, 1 is a hermetic refrigerant compressor, and 2 is an accumulator. The refrigerant compressor 1 is provided with a compression mechanism portion 4 at the lower portion in the sealed case 3 and an electric motor portion 5 at the upper portion. The compression mechanism unit 4 and the electric motor unit 5 are connected via a rotating shaft 6.
[0025]
The electric motor unit 5 includes a stator 8 fixed to the inner surface of the sealed case 3 and a rotor 9 disposed inside the stator 8 via a predetermined gap and having the rotating shaft 6 inserted therein. Composed.
[0026]
The compression mechanism unit 4 includes two cylinders 11A and 11B that are arranged below the rotary shaft 6 with a partition plate 10 interposed therebetween. The upper cylinder 11A is attached and fixed to the main bearing 12 at the upper surface. The auxiliary bearing 13 is attached and fixed to the lower surface portion of the lower cylinder 11B.
[0027]
The upper and lower surfaces of the cylinders 11A and 11B are partitioned by the partition plate 10, the main bearing 12 and the auxiliary bearing 13, and cylinder chambers 15a and 15b are formed therein. The cylinder chambers 15a and 15b are configured with so-called rotary compression mechanisms 16A and 16B that drive the rollers eccentrically as the rotary shaft 6 rotates and partition the cylinder chamber into a high pressure side and a low pressure side by vanes. The Cylinder chambers 15a and 15b in both cylinders 11A and 11B are communicated with the accumulator 2 through conducting tubes 17a and 17b, respectively.
[0028]
On the other hand, a discharge refrigerant pipe 19 is connected to the upper surface of the sealed case 3 and communicates with a condenser (not shown). A suction refrigerant pipe 21 is connected to the upper surface of the accumulator 2 and communicates with an evaporator (not shown). An expansion mechanism is connected between the condenser and the evaporator, and a refrigeration cycle is formed that sequentially communicates with the accumulator 2 via the refrigerant compressor 1 -condenser-expansion mechanism-evaporator.
[0029]
FIGS. 2A and 2B are a plan view and a front view of the electric motor unit 5, and the rotor 9 is disposed inside the stator 8. The stator 8 includes a yoke portion 32 that is an annular yoke, and a plurality (six) of teeth portions 33 that are radially disposed inside the yoke portion at a predetermined interval. A laminated stator core 30 is provided.
[0030]
As will be described later, the teeth portion 33 is covered with an insulating member 40, and a winding 31 is provided through the insulating member. 2A shows the winding 31 with the insulating member 40 omitted, and FIG. 2B shows a state in which a part of the insulating member 40 protrudes from the upper and lower end surfaces of the stator core 30.
[0031]
Windings 31 for the stator core 30 are provided so that the number of slots (tooth portions 33) in the stator 8 is six and the number of poles of the rotor 9 is set to four.
[0032]
The rotor 9 includes a yoke portion 35 and a plurality (four) of permanent magnets 36 embedded in the yoke portion 35. The permanent magnet 36 is assembled in a non-magnetized state, and is magnetized after being assembled as the motor unit 5.
[0033]
FIG. 3 shows a single-type insulating member 40A fitted into the six teeth portions 33 from the upper side and the lower side, and twelve of these insulating members are prepared in total.
[0034]
The insulating member 40A includes an inner flange portion A, an outer flange portion B, and a body portion C that connects the inner and outer flange portions A and B to each other. In particular, a portion that is formed in a substantially U shape in a cross-sectional state of the body portion C and that is in close contact with the end surface of the tooth portion 33 when assembled is called a winding body portion c, and is attached to both ends of the winding body portion. A pair of surfaces that are integrally provided along both side surfaces of the tooth portion 33 are referred to as tooth insulating portions d and d, and f is a tip of the tooth insulating portion d.
[0035]
In the figure, the x marks of (1) to (4) indicate the position of the gate which is a resin injection port when the insulating member 40 is molded, and there is no difference between the inner flange portion A and the outer flange portion B. It is provided so as to face at least one of them.
[0036]
Further, an insulating member 40B as shown in FIG. 4 may be used. In the case of this insulating member 40B, it is an overall type composed of an upper insulating member 40Ba fitted from the upper side and a lower insulating member 40Bb fitted from the lower side over all six tooth portions 33, Therefore, it is sufficient if there are two.
[0037]
Fig.5 (a) shows the planar view of upper side insulation member 40Ba inserted from the upper side of the said teeth part 33 which comprises the insulation member 40B of the whole type, The same figure (b) of the figure (a) is shown. A bb cross section is shown.
[0038]
FIG. 6A shows a plan view of a lower insulating member 40Bb that is fitted from the lower side of the tooth portion 33, which constitutes an overall type of insulating member 40B, and FIG. A bb cross section is shown. FIG. 7 is a perspective view of an overall type insulating member 40B, of which an upper insulating member 40Ba.
[0039]
As shown in FIGS. 5 (a), 6 (a), and 7, the upper and lower side insulating members 40Ba and 40Bb are provided with an inner flange portion A and an outer flange portion B, and the inner and outer flange portions A and B. And a body portion C connecting the two.
[0040]
In particular, as shown in FIGS. 5 (b) and 6 (b), a surface that is in close contact with one end surface of the tooth portion 33 in a state in which the body portion C is in cross section is referred to as a winding body portion c. The opposing surfaces along the both side surfaces are referred to as a tooth insulating portion d, and f is the tip of the tooth insulating portion d.
[0041]
Insulating member 40 described above(For details, refer to 40A and 40B, the same applies hereinafter.) As shown in detail in FIGS. 5 (b) and 6 (b), the winding is applied to the corner portion 41 that forms the boundary between the winding body portion c and the teeth insulating portion d. It is characterized by providing an R chamfer that is 1/2 or more of the wire diameter of the wire 31.
[0042]
In order to confirm the effect of the insulating member 40 described above, a winding is applied to an insulating member in which the R chamfer size of the corner portion 41 is variously changed, the degree of damage to the insulating coating of the winding, and the deformation of the winding cross section. The state, the dent deformation at the corner, the broken state of the inner flange A after magnetization, and the like were evaluated.
[0043]
Specifically, the winding work of winding the winding 31 after fitting the insulating member 40 in the teeth portion 33 constituting the stator core 30 is performed by setting a constant tension and a winding speed. At this time, the load applied to the inner flange A of the insulating member 40 is 50 to 100 kgf.
[0044]
Further, a PPS resin (polyphenylene sulfide) material is selected as the material for the insulating

members

40A and 40B.
[0045]
The wire diameter of the winding 31 is φ1.0 mm, and as shown in FIG. 8B, the R chamfering of the corner portion 41 is R: 0.1, R: 0.3, R: 0.5, R : 1.0 and R: 2.0 (mm).
[0046]
FIGS. 9A to 9D illustrate details of the evaluation obtained under the above conditions. That is, in FIG. 9A, the damaged state of the insulating coating 42 covering the winding 31 after winding was observed. In FIG. 9B, the amount of deformation of the winding 31 after winding with respect to the initial wire diameter was measured. In FIG.9 (c), the hollow amount of the corner part 41 of the insulating member 40 is measured, and the gg cross section of FIG.9 (c) is shown to the same figure (g). In FIG. 9 (d), the presence / absence of a crack at the root of the inner flange A after magnetization was confirmed.
[0047]
The above four items were evaluated, and the evaluation results are summarized in Table 1 below. Note that the deformation of the winding after the winding and the depression of the corner portion 41 are shown as relative values when the specification of (3) R: 0.5 (mm) in Table 1 is 1.0.
[0048]
[Table 1]

[0049]
From the above results, according to the specifications (3) to (5), the insulation coating 42 on the surface of the winding 31 is not damaged, and the deformation of the winding 31 and the insulating member 40 can be small. It was also found that no crack occurred at the base of the inner flange A after magnetization.
[0050]
On the other hand, according to the specifications (1) and (2), since the R chamfer dimension is small, there is stress concentration at the corner portion 41, the insulating coating 42 is damaged, the winding 31 is deformed, and the corner The dent in the part 41 becomes large. Furthermore, it has been found that the stress is concentrated in the dent portion with respect to the force that the inner flange portion A tends to fall toward the rotor 9 during magnetization, and cracks are generated starting from this dent.
[0051]
In other words, by setting the R chamfer to 1/2 (0.5 part) or more of the wire diameter, stress concentration during winding can be relaxed and reliability can be improved. However, if the R chamfer is increased more than necessary, the corner portion 41 becomes thin and the strength of the insulating member 40 is reduced. Therefore, the R chamfer is preferably in the range of 1/2 to 4 times the wire diameter.
[0052]
  A configuration as shown in FIG. 10 may be used.
  Here, the surface of the winding drum portion c in the drum portion C constituting the insulating member 40 is formed as a convex portion 44 having a gentle convex shape. The convex portion 44 has a height (convex height) that comes into contact with the winding 31 when it is wound.
[0053]
As shown in FIG. 8A, in the normal configuration, a winding gap 43 is formed between the winding body c and the winding 31, and stress concentrates on the corner portion 41. However, by forming the convex portion 44 shown in FIG. 10, the convex portion receives a part of the tension of the winding 31 and the winding gap as described above does not occur. Therefore, the contact force of the winding 31 with respect to the corner portion 41 is relaxed, the damage to the insulating coating 42 of the winding is prevented, and the depression of the corner portion 41 can be prevented.
[0054]
The convex portion 44 depends on various conditions such as the distance between both corner portions 41 of the winding body portion c, the R shape of the corner portion 41, the wire diameter and elastic force of the winding 31, and the tension of the winding 31. The effect is greater as the contact length between the winding 31 and the insulating member 40 is longer.
[0055]
Note that the cross-sectional shape of the convex portion 44 is preferably a gentle arc shape over the entire surface as shown in FIG. 10, but is not limited to this, and only the central portion as shown in FIG. Convex part 44a may be sufficient, and conversely, as shown in FIG. 11B, the same effect can be obtained by forming a concave part at the center part and forming convex parts 44b on both sides thereof.
[0056]
  Also, as shown in FIGS. 12 and 13, hereAs shown in FIG. 12, the relationship between the thickness T1 of the tip end f of the tooth insulating portion d and the base side of the tip and the thickness T2 of the corner portion 41 is set to T1> T2.
[0057]
After the above dimension setting, as shown in FIG. 13, the upper side insulating member 40Ba and the lower side insulating member 40Bb are fitted. When the overlap margins f obtained by overlapping the tips f of the insulating members contact each other, the overlap margins are pressed down and the gap between the overlap margins f is filled, so that the insulation characteristics are improved.
[0058]
Due to the relationship of T1> T2 described above, the contact thickness is particularly when T1 winds the winding 31. That is, by having this thickness T1, a part of the tension of the winding 31 is received, and the contact force of the winding with respect to the corner portion 41 is relaxed, and the same effect as the above-described convex portion 44 is obtained. In addition, if the cross-sectional shape of the winding drum portion c is the same gentle arc-shaped surface as the convex portion 44, it is more effective.
[0059]
  Furthermore, FIG. 12 and FIG.The configuration shown in FIG.That is, as described above with reference to FIG. 10, the relationship between the thickness Tc of the convex portion 44 of the winding drum portion c and the distal end f proximal side thickness T1 of the tooth insulating portion d is set to Tc> T1.
[0060]
This is because the distance between the corner portions 41 of the upper-side insulating member 40Ba and the lower-side insulating member 40Bb is longer than the distance between the both-side corner portions 41 of the winding body portion c. Can touch well.
[0061]
On the other hand, the thickness Tc of the winding body portion c needs to increase the height of the convex portion 44 because the R chamfering of the insulating member corner portion 41 is large and the distance between the corner portions 41 is short. Therefore, Tc must be thick. Therefore, the effect is further exhibited by setting Tc> T1.
[0062]
  In additionAgain, FIG. 1 and FIG. 2 (a)As shown inIn the DC motor as the electric motor unit 5, the permanent magnet 36 of the rotor 9 needs to be magnetized at the time of assembly. However, during this magnetization, a magnetizing current may flow through the winding 31 of the stator 8, and deformation of the flange portion of the insulating member 40 may occur due to the electromagnetic force of the winding 31.
[0063]
At this time, cracks were generated starting from the depression formed in the insulating member 40. As shown in the results of Table 1, by adopting the insulating member 40 having the above-described characteristics, electromagnetic force Good results were obtained by preventing cracking due to.
[0064]
  In addition, another means14 (a) to 14 (c) and FIGS. 15 (a) and 15 (b).
  First, referring to FIG. 15, FIG. 15A is a schematic configuration of an injection molding process, and includes an injection molding machine 60, a mold die 46, a movable die 47 and a fixed side constituting the mold die. A mold 48 and a dividing surface 49 (parting surface) of each

mold

47 and 48 are shown. FIG. 4B shows only the mold 46 in an enlarged manner.
[0065]
To explain from the injection molding process by the injection molding machine 60, the resin material is put into the hopper 63 connected to the injection molding machine 60. The screw 62 rotates in the cylinder 61 of the processing machine, and the resin material put into the hopper 63 is sent to the tip side. In the middle of this, the charged resin material is heated and melted by the heater H embedded in the thickness of the cylinder 61. The fluorine resin melted by the rotation and retraction of the screw 62 is accumulated on the tip side, and the molten fluorine resin is injected into the mold 46 by the straight advance of the screw 62.
[0066]
In the mold 46, the temperature is set so that the molten resin is cooled and solidified. The molten resin injected from the processing machine 60 through the injection path 53 of the fixed mold 48 constituting the mold 46 is introduced into the cavity from the injection port 54 serving as a gate, and collected here. The insulating member 40 is molded by cooling and solidifying based on a predetermined time setting. Note that the position of the injection port 54 serving as the gate is provided in at least one of the inner flange portion A and the outer flange portion B of the trunk portion C.
[0067]
At the timing when the molten resin is cooled and solidified in the cavity, the movable mold 47 is driven backward, and the movable mold 47 and the fixed mold 48 are divided at the position of the dividing surface 49. At that time, the injection port 54 is separated from the molded insulating member 40.
[0068]
The protruding plate 52 moves forward with respect to the insulating member 40 remaining in the movable mold 47, and the protruding pin 50 provided here pushes out the insulating member 40 and removes it from the mold 46.
[0069]
More specifically, as shown in FIG. 4B, the fixed mold 48 is divided into a first divided mold 48a and a second divided mold 48b, and the divided mold 48a, The injection path 53 can be taken out by opening 48b.
[0070]
Then, after the insulating member 40 and the cooled and solidified resin in the injection path 53 are removed from the divided molds 48a and 48b, the movable mold 47 and the fixed mold 48 are closed, and the same process is repeated again. It becomes.
[0071]
14 (a) to 14 (c) are partial cross-sectional views showing the state of the mold dividing surface 49 of the portion constituting the tooth insulating portion d. A dividing surface 49 is provided at a position corresponding to the tip e of the tooth insulating portion d.
[0072]
As the shape in the thickness direction of the tooth insulation part d, it is necessary for dividing the fixed side mold 48 and the movable side mold 47 shown in FIG. 14B and for taking out the insulating member 40 shown in FIG. 14C. An inclination (taper) is provided. Therefore, the thickness of the tooth insulating portion d is in the relationship of the winding drum portion c <the tip e, and by providing such a dividing surface 49, the resistance when the insulating member 40 is taken out from the mold is reduced. Generation of cracks can be prevented.
[0073]
Specifically, since the stator core 30 is composed of laminated magnetic steel plates, the corner of the tooth portion 33 cannot be chamfered or the like, and the corner portion 41 of the insulating member 40 located at this corner is also Can only be chamfered. If the resistance at the time of taking out the molded insulating member 40 from the mold is large, concentrated stress is generated in the corner portion 41 and causes cracking.
[0074]
However, here, due to the presence of the dividing surface 49 described above, one side of the tooth insulating portion d is opened simultaneously with the opening of the movable mold 47. Since the insulating member 40 remaining in the movable mold 47 is pushed out by the protruding pin 50, the frictional resistance between the movable mold 47 and the insulating member 40 is greatly reduced, and the corner portion 41 Reduces the load to prevent cracking.
[0075]
Furthermore, since the burr 51 generated on the dividing surface 49 is formed at a position farthest from the corner portion 41 where the winding 30 receives the stress most, even if the burr 51 remains in the manufacturing process, the stress on the winding 30 is increased. And the occurrence of defects such as damage to the insulating coating 42 can be prevented.
[0076]
In terms of the burr removing process, the burr 51 is generated at the tip e. Therefore, the burr removing process is easier as compared with a burr generated in a deep position such as in the tooth insulating portion d. Further, with this mold configuration, the relationship of the thickness T1> T2 of the teeth insulating portion d of claim 3 can be easily formed.
[0077]
The above-described dividing surface 49 is more effective as it is closer to the tip e of the insulating member 40 teeth insulating portion d. Although it is desirable to provide the dividing surface 49 at the forefront, as shown in FIG. 13, the upper and lower insulating members 40Ba and 40Bb fitted from the lower side need to be formed with an overlap margin f, and the shape of the overlap margin f Depending on the mold configuration, it may be difficult.
[0078]
A mold configuration as a comparative example is shown in FIG. That is, the following mold configuration is also conceivable.
Here, the dividing surface 49 is provided in the vicinity of the corner portion 41, and the teeth insulating portions d are all formed on the movable-side mold 47. Therefore, in order to provide an inclination necessary for taking out the insulating member 40 from the movable mold 47, the thickness of the tooth insulating portion d has a relationship of the winding drum portion c <tip e (T1 <T2).
[0079]
In addition, since the insulation distance between the stator core 30 and the winding 31 cannot be increased, it is necessary to reduce the thickness and the inclination. Therefore, the resistance when the insulating member 40 is taken out from the movable mold 47 is large, and there is a possibility that a crack may occur in the corner portion.
[0080]
  Moreover, as shown in FIG. 17, it demonstrated with FIG. 14 (a)-(c).Assuming the mold configuration, the relationship between the insulating member surface roughness 46a formed by the fixed mold 48 and the insulating member surface roughness 46b formed by the movable mold 47 is such that 44a <44b. It is set.
[0081]
Basically, the surface roughness of the insulating member 40 is determined by the surface roughness of the mold because the mold surface roughness is transferred. Specifically, if the surface roughness of the stationary mold 48 is set to be small, the surface roughness 46a of the insulating member 40 becomes small.
[0082]
From this setting, when the fixed side mold 48 and the movable side mold 47 are opened, the frictional resistance of the insulating member 40 with respect to the fixed side mold 48 is reduced, and the stress on the insulating member 40 is reduced. To do. The load on the corner portion 41 is reduced to prevent the occurrence of cracks. Since the winding 31 is wound on a surface having a small surface roughness 46a of the insulating member, there is also an effect of preventing the winding insulating film 42 from being damaged.
[0083]
  further18 (a) and 18 (b)likeThe overlapping distance 55 of the overlap margin f at the front ends of the insulating members 40Ba and 40Bb fitted from the upper side and the lower side is 2 mm in FIG. 18 (a) and 10 mm in FIG. 18 (b).
[0084]
Since the stator core 30 is formed by laminating magnetic steel plates, manufacturing variations are likely to occur in the thickness direction. For this reason, the above-mentioned overlap allowance f is set as a length 56 in consideration of the distance 55 overlapping with the dimensional tolerance of the manufacturing variation.
[0085]
Here, as described above, since the relationship between the thicknesses T1 and T2 of the tooth insulating portion d is T1> T2 and the overlap margin f is pressed by the winding 31, the distance 2 mm as shown in FIG. Even so, a predetermined insulation characteristic was obtained.
[0086]
Further, since the thickness of the overlap allowance f can be increased and the resin can easily flow, as shown in FIG. 18B, molding can be performed even if the distance 55 is extended to 10 mm. Therefore, the overlapping distance 55 of the overlap allowance f is preferably in the range of 2 mm to 10 mm from the balance between the insulating characteristics and the moldability.
[0087]
In addition, in the mold configuration as the comparative example described above with reference to FIG. 16, when the relationship between the thicknesses of the tooth insulation portions is T1 <T2, a gap is generated between the overlap allowance and the winding, and the insulation characteristics are lowered. It was necessary to set to 4 mm.
[0088]
Moreover, since the thickness of the overlap allowance becomes small, the resin does not flow, and the distance is limited to 6 mm from the viewpoint of molding. In other words, it is necessary to secure a long distance from the surface of the insulation characteristics, but the distance is limited in the molding process, and it is necessary to suppress the manufacturing variation of the stator core as much as possible.
[0089]
Therefore, by configuring the distance 55 in the range of 2 to 10 mm as in the above-described embodiment, it is possible to cope with large manufacturing variations of the stator core 30 and the productivity is improved.
[0090]
  Also, Shown in FIG.You may do it.
[0091]
That is, the insulating member 40B that is fitted from the upper side and the lower side._a1, 40B_b1A separate intermediate insulating member 57 having an overlap f that matches with the above is provided. The intermediate insulating member 57 has a cross section having the same shape as the tooth insertion portion d, and the upper and lower side insulating members 40B._a1, 40B_b1The overlap margin f is formed. By interposing the intermediate insulating member 57 between them, even if the thickness of the stator core 33 is increased, it is not necessary to prepare a new mold, and the insulating member 40B can be used as it is.
[0092]
These electric motor parts 5 improve the efficiency of the compression mechanism part 4 and compensate for the lack of torque with the thickness of the stator core 33. For this reason, by providing the intermediate insulating member 57, the use range of the insulating member 40B is expanded and the productivity is excellent.
[0093]
【The invention's effect】
As described above, according to the present invention, damage to the insulating coating of the winding and the insulating member can be improved, insulation failure and breakage of the insulating member when magnetized can be prevented, and products with different stator core thicknesses can be prevented. An insulating member having the same shape can be employed, thereby improving productivity and improving reliability.
[Brief description of the drawings]
FIG. 1 is a sectional view of a refrigerant compressor showing an embodiment of the present invention.
FIG. 2 is a plan view and a front view of an electric motor unit according to the embodiment.
FIG. 3 is a front view of a split type insulating member according to the embodiment;
FIG. 4 is a diagram showing insulating members and gate positions having different specifications according to the embodiment;
FIGS. 5A and 5B are a plan view and a partial cross-sectional view of an upper-side insulating member of the overall type according to the embodiment;
FIGS. 6A and 6B are a plan view and a partial cross-sectional view of a lower-side insulating member of the overall type according to the embodiment;
FIG. 7 is a perspective view of the upper-side insulating member of the overall type according to the embodiment;
FIG. 8 is a partial cross-sectional view of the tooth insulating portion fitted into the tooth portion and a surface for explaining R of the corner portion according to the embodiment;
FIG. 9 is a perspective view, a front view, and a partial cross-sectional view for explaining a damaged state of the embodiment.
FIG. 10 is a partial cross-sectional view showing a convex portion of an insulating member according to the embodiment.
FIG. 11 is a partial cross-sectional view showing a convex portion of another modification of the insulating member according to the embodiment.
FIG. 12 is a partial cross-sectional view showing the thickness of a tooth insulating portion of the insulating member according to the embodiment.
FIG. 13 is a partial cross-sectional view showing the thickness of the teeth insulating portion when the upper and lower insulating members are fitted into each other according to the embodiment;
FIG. 14 is a partial cross-sectional view showing the mold configuration and the operation during molding according to the embodiment.
FIG. 15 is a sectional view showing an injection molding machine and a mold according to the embodiment, and a sectional view of the mold.
FIG. 16 is a partial cross-sectional view showing a mold configuration and an operation during molding as a comparative example.
FIG. 17 is a partial cross-sectional view illustrating a surface state of a mold and an insulating member according to the embodiment.
FIG. 18 is a partial cross-sectional view showing the overlapping of the upper and lower sides of the insulating member according to the embodiment.
FIG. 19 is a partial cross-sectional view showing a configuration of a separate insulating member according to the embodiment.
[Explanation of symbols]
4 ... compression mechanism,
8 ... Stator,
9 ... rotor,
5 ... Electric motor part,
32 ... Yoke part,
33 ... Teeth club,
30 ... Stator core,
40. Insulating member,
40A ... insulating member,
40B ... insulating member,
31 ... Winding,
A ... Inner buttock,
B ... Outer buttocks,
C ... trunk,
c ... winding body,
d: Teeth insulation,
41 ... Corner,
44 ... convex part,
47. Movable side mold,
48 ... fixed side mold,
57: Intermediate insulating member.

Claims

In a refrigerant compressor provided with an electric motor unit composed of a compression mechanism unit that compresses and discharges a refrigerant, and a stator and a rotor that drive the compression mechanism unit,
The stator is integrally formed with a yoke portion, which is an annular yoke, and a plurality of teeth portions are installed radially, and windings are wound around each tooth portion via an insulating member,
The insulating member is a resin molded product, and is composed of an inner flange portion and an outer flange portion, and a trunk portion in which a winding is wound by connecting the inner and outer flange portions.
A refrigerant compressor characterized in that an R chamfer having a radius not less than 1/2 and not more than 4 times the wire diameter of the winding is provided at a corner portion of the body portion .