JP5981089B2 - Insulating resin sheet for fixing coil, stator for motor using insulating resin sheet for fixing coil, and method for manufacturing stator for motor - Google Patents

Description

  The present invention relates to an insulating resin sheet for fixing a coil, a stator for a motor using the insulating resin sheet for fixing a coil, and a method for manufacturing a stator for a motor.

  A slot is formed in the stator core of the stator for the motor, and a plurality of coil conductors are accommodated in the slot. In that case, it is necessary to form an insulating layer between the slot inner peripheral surface and the plurality of coil conductors. Examples of a method for providing this insulating layer in the slot include a resin impregnation method and a method using an insulating sheet.

  As a method using an insulating sheet, for example, Patent Document 1 uses an insulating sheet in which a thermosetting resin in a semi-cured state is laminated on both surfaces of an insulating film substrate, and wraps a plurality of coil conductors with this insulating sheet. It describes that a stator for a motor is manufactured by housing it in a slot.

  Patent Document 2 discloses, as an insulating sheet-like molded body, a filler composed of a minute hollow glass sphere having a specific particle size, particle density, and particle size gradient, and containing a specific element in a predetermined amount or less. A sheet blended in a resin is described, and in Patent Document 3, an ultraviolet transmissive filler composed of organic and inorganic hollow fine particles is blended in an ultraviolet curable resin composition as an insulating sheet. A sheet is described.

  In addition, in Patent Document 4, in order to eliminate a gap remaining between the strands of the wire coils, an expansion agent layer is attached on both sides with a rigid insulating sheet interposed between the rows of the wire coils. It is described that an agent-bonded insulating sheet is inserted.

JP 2009-33889 A JP 2002-100238 A JP 2002-249669 A JP-A-6-225489

  For example, when a resin sheet made of an epoxy resin composition (also referred to as “epoxy prepreg sheet”) is used as the insulating sheet, the epoxy resin composition generally has a high relative dielectric constant (for example, an epoxy resin composition The dielectric constant is about 3.5), and the partial discharge starting voltage in the unit thickness of the sheet is lowered. Therefore, in a high-voltage motor, when using a resin sheet made of an epoxy resin composition as an insulating sheet used when accommodating a plurality of coil conductors in a stator core, the resin sheet must be designed to have a large thickness, As a result, the space factor of the coil conductor in the slot is lowered.

Further, an insulating film is generally formed on the outer peripheral surface of the coil conductor, and this insulating film is also called a coil film. Here, for example, in the case of a resin sheet made of an epoxy resin composition, the resin sheet is firmly bonded to the coil film by a hydroxyl group (—OH group) which is one of the functional groups of the epoxy resin composition. Due to the thermal expansion and cooling shrinkage of the coil conductor that accompanies use and stoppage, the coil film may be repeatedly pulled to cause cracks in the film.

  In addition, when the insulating sheet is made of only the resin composition, the resin sheet is placed on the inner circumferential surface of the slot, and after inserting a plurality of coil conductors, when heated and cured as necessary, the resin sheet and There may be a case where the void in the inner peripheral surface of the slot exists even after the resin sheet is cured. In such a case, the coil conductor in the slot is likely to be insufficiently fixed, the thermal conductivity is lowered, and the insulation may be lowered.

  The present invention has been made in view of the above problems, and compared with the prior art, the film thickness of the insulating sheet is reduced to improve the space factor of the coil conductor in the slot in the stator core of the motor. Insulation resin sheet for coil fixing and insulation for coil fixing, which suppresses damage to the coil film against thermal shock such as expansion and cooling shrinkage, and also improves the fixability of the coil conductor in the slot and improves the insulation. A stator for a motor using a resin sheet and a method for manufacturing the stator for a motor are provided.

  In order to achieve the above object, the coil fixing insulating resin sheet, the motor stator using the coil fixing insulating resin sheet of the present invention, and the method of manufacturing the motor stator have the following characteristics.

(1) a coil bonding resin layer having an imide-modified unsaturated polyester resin and a low dielectric filler having a relative dielectric constant of 2 or less, a stator core bonding resin layer having an amine curable rubber-dispersed epoxy resin and an expansion filler, have a, the low dielectric filler comprises a mixture of calcium carbonate and talc, wherein the amine-curable rubber-dispersed epoxy resin is a mixture of novolak type epoxy resin, rubber-modified epoxy resins, phenoxy resins, and amine curing agent This is an insulating resin sheet for fixing coils.

  Unit thickness of each layer of coil bonding resin layer and stator core bonding resin layer because imide-modified unsaturated polyester resin and amine-curing rubber-dispersed epoxy resin with low relative dielectric constant are used compared to conventional epoxy resin compositions The partial discharge start voltage at is higher than that of the resin sheet using the epoxy resin composition. As a result, the total film thickness of the insulating resin sheet for fixing the coil can be reduced, and the space factor of the coil conductor in the slot in the stator core of the motor is improved as compared with the prior art. In addition, imide-modified unsaturated polyester resins and amine-curing rubber-dispersed epoxy resins have less adhesive functional groups (for example, hydroxyl groups) than conventional epoxy resin compositions, and therefore have an appropriate bonding state with the coil coating. The crack of the coil coating is suppressed against thermal shock such as thermal expansion and cooling contraction of the coil conductor. Here, the “coil film” means an insulating film provided on the outer peripheral surface of the coil conductor, and the coil film that may cause a crack is formed by insulating a plurality of coil conductors described later. It refers to the coil coating existing on the outer periphery of the coil conductor group. Further, the expansion filler contained in the stator core bonding resin layer expands due to heat or the like, so that the space between the outer peripheral surface of the coil conductor group and the coil fixing insulating resin sheet and the inner wall surface of the slot and the coil fixing insulating resin Since the gap between the sheet and the sheet is fixed without any gap, the fixing property of the coil conductor in the slot is improved and the insulation is also improved.

  (2) The coil fixing insulating resin sheet according to (1), wherein the coil bonding resin layer is a coil fixing insulating resin sheet further including an expansion filler.

  Furthermore, since the expansion resin is included in the coil bonding resin layer, it expands due to heat or the like together with the expansion filler included in the stator core bonding resin layer, and thereby the outer peripheral surface of the coil conductor group and the insulating resin sheet for fixing the coil And between the inner wall surface of the slot and the insulating resin sheet for fixing the coil can be fixed without a gap.

(3) In the insulating resin sheet for fixing a coil according to the above (1) or (2), a heat resistant film is provided between the coil bonding resin layer and the stator core bonding resin layer. It is an insulating resin sheet.

  By providing the heat resistant film between the coil bonding resin layer and the stator core bonding resin layer, the rigidity of the insulating resin sheet for fixing the coil is secured.

(4) A coil bonding resin layer having an imide-modified unsaturated polyester resin, a low dielectric filler having a relative dielectric constant of 2 or less, and an expansion filler, and a stator core bonding resin layer having an amine curable rubber-dispersed epoxy resin. The low dielectric filler includes a mixture of calcium carbonate and talc, and the amine curable rubber-dispersed epoxy resin is a mixture of a novolac epoxy resin, a rubber-modified epoxy resin, a phenoxy resin, and an amine curing agent. It is an insulating resin sheet for fixing.
(5) A stator for a motor in which a coil conductor group formed by insulating a plurality of coil conductors is accommodated in a slot in the stator core, the stator core having a plurality of slots, and accommodated in the slot And a coil fixing insulating resin sheet covering an outer peripheral surface of the coil conductor group, and the coil fixing insulating resin sheet is any one of the above (1) to ( 4 ). The coil fixing insulating resin sheet according to claim 1, wherein the coil conductor group and an outer peripheral surface of the coil conductor group are in contact with each other and the inner wall of the slot and the stator core bonding resin layer are in contact with each other . insulating said expansion filler resin in the sheet is a motor stator with coil fixing the insulating resin sheet that has become a thermally expanded state.

  The motor stator has a high space factor of the coil conductor in the stator core slot, and the coil conductor group is fixed in close contact with the slot, so when a conventional stator of the same size is mounted on the motor High output can be obtained.

  (6) The outer periphery of the coil conductor group in which the coil bonding resin layer of the coil fixing insulating resin sheet according to any one of (1) to (4) is formed by insulating a plurality of coil conductors. The insulating resin sheet for fixing the coil is wound around the outer periphery of the coil conductor group so as to be in contact with the surface, a temporary coil assembly is formed, the temporary coil assembly is inserted into a slot of the stator core, and heated to fix the coil Manufacture of a stator for a motor in which an insulating resin sheet is expanded and cured to fix between an outer peripheral surface of a coil conductor group and the insulating resin sheet for fixing a coil and between an inner wall surface of a slot and the insulating resin sheet for fixing a coil Is the method.

  A coil temporary insulating assembly is formed by winding a coil fixing insulating resin sheet around the outer periphery of a coil conductor group formed by insulating a plurality of coil conductors in advance. improves.

  (7) The outer periphery of the coil conductor group in which the coil bonding resin layer of the insulating resin sheet for fixing a coil according to any one of (1) to (4) is formed by insulating a plurality of coil conductors. A coil conductor group is fitted into the coil fixing insulating resin sheet so as to be in contact with the surface to form a coil temporary assembly, and the coil temporary assembly is inserted into a slot of a stator core and heated to heat the coil fixing insulating resin. A method for manufacturing a motor stator, in which a sheet is expanded and cured, and an outer peripheral surface of a coil conductor group and the insulating resin sheet for fixing a coil and an inner wall surface of a slot and the insulating resin sheet for fixing a coil are fixed. is there.

  Compared with the case where the coil fixing insulating resin sheet is wound around the outer periphery of the coil conductor group to form a temporary coil assembly, the coil conductor group is simply fitted into the coil fixing insulating resin sheet, and the assembly efficiency is further improved. To do.

(8) The coil fixing insulation is previously set so that the stator core bonding resin layer of the coil fixing insulating resin sheet according to any one of (1) to (4) is in contact with the inner wall surface of the stator core slot. A resin sheet is bent into a slot shape, inserted into the slot, and a coil conductor group formed by insulating a plurality of coil conductors is in contact with the coil bonding resin layer of the coil fixing insulating resin sheet. And the coil fixing insulating resin sheet is expanded and cured by heating, between the outer peripheral surface of the coil conductor group and the coil fixing insulating resin sheet, the inner wall surface of the slot, and the coil fixing insulating resin sheet, It is a manufacturing method of the stator for motors which adheres between.

  Since the insulating resin sheet for fixing the coil is previously bent into a slot shape and inserted into the slot, the insulating resin sheet for fixing the coil is surely positioned in the slot. Further, since the coil conductor group is inserted using the inserted coil fixing insulating resin sheet as a guide, the coil conductor group is inserted between the inner wall surface of the slot and the coil fixing insulating resin sheet and at the outer periphery of the coil conductor group. The gap between the surface and the insulating resin sheet for fixing the coil is greatly reduced.

  According to the present invention, the insulation sheet is made thinner than before, so that the space factor of the coil conductor in the slot in the stator core of the motor is improved, and thermal shock such as thermal expansion and cooling contraction of the coil conductor is achieved. On the other hand, the damage of the coil film is suppressed, and the fixing property of the coil conductor in the slot is improved.

It is a partial perspective view which shows an example of the stator core of a motor. It is a fragmentary sectional view showing an example of the insulating resin sheet for coil fixation in the present invention. It is a fragmentary sectional view which shows another example of the insulating resin sheet for coil fixation in this invention. It is a fragmentary sectional view which shows another example of the insulating resin sheet for coil fixation in this invention. It is a fragmentary sectional view which shows another example of the insulating resin sheet for coil fixation in this invention. It is a fragmentary sectional view which shows another example of the insulating resin sheet for coil fixation in this invention. It is a fragmentary sectional view which shows another example of the insulating resin sheet for coil fixation in this invention. It is a fragmentary sectional view showing an example of the structure of the stator for motors in the present invention. It is process drawing which shows an example of the manufacturing method of the stator for motors in this invention. It is process drawing which shows another example of the manufacturing method of the stator for motors in this invention. It is process drawing which shows another example of the manufacturing method of the stator for motors in this invention. It is a figure which shows the other example of the slot mounting form of the insulating resin sheet for coil fixation in this invention.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

[Insulating resin sheet for fixing coils]
FIG. 1 is a partial perspective view showing an example of a stator core of a motor in a state where a plurality of coil conductive wires to be described later are not filled in the teeth viewed from the end surface 10A of the stator core. As shown in FIG. 1, the stator core 10 includes teeth 1 to 6 and slots 11 to 18 provided between the teeth 1 to 6. Each of the teeth 1 to 6 includes a plurality of coil conductors. Are filled and formed.

  The configuration in this embodiment (hereinafter abbreviated as “resin sheet”) is illustrated in FIGS. 2 to 7. First, as shown in FIG. 2, a resin sheet 100 a includes a coil bonding resin layer 20 a having an imide-modified unsaturated polyester resin 22 and a low dielectric filler 24 having a relative dielectric constant of 2 or less, and an amine curable rubber-dispersed epoxy. A stator core bonding resin layer 30a having a resin 32 and an expansion filler 34 is provided, and one surface of the coil bonding resin layer 20a and one surface of the stator core bonding resin layer 30a are bonded together.

  Since the imide-modified unsaturated polyester resin 22 and the amine curable rubber-dispersed epoxy resin 32 having a low relative dielectric constant are used as compared with the conventional epoxy resin composition, each of the coil bonding resin layer 20a and the stator core bonding resin layer 30a is used. The partial discharge start voltage at the unit thickness of the layer is higher than that of the resin sheet using the epoxy resin composition. Thereby, the total film thickness of the resin sheet 100a can be made thin, and the space factor of the coil conductor in the slot in the stator core of the motor is improved as compared with the prior art. In addition, since the imide-modified unsaturated polyester resin 22 and the amine curable rubber-dispersed epoxy resin 32 have fewer functional groups (for example, hydroxyl groups) having high adhesiveness than conventional epoxy resin compositions, appropriate bonding with the coil coating is possible. The state is maintained and cracking of the coil coating is suppressed against thermal shock such as thermal expansion and cooling contraction of the coil conductor. Further, the expansion filler 34 contained in the stator core bonding resin layer 30a expands due to heat or the like, so that the space between the outer peripheral surface of the coil conductor group and the resin sheet 100a and the space between the inner wall surface of the slot and the resin sheet 100a. Is fixed without any gap, so that the fixing property of the coil conductor in the slot is improved and the insulating property is also improved.

  A resin sheet 100b shown in FIG. 3 is provided with a heat resistant film 40 between the coil bonding resin layer 20a and the stator core bonding resin layer 30a of the resin sheet 100a shown in FIG. The resin layer 20a for the stator is bonded to the other surface of the heat-resistant film 40 with the resin layer 30a for joining the stator core. Thereby, the rigidity of the resin sheet 100b is ensured.

  A resin sheet 100c shown in FIG. 4 includes an imide-modified unsaturated polyester resin 22, a low dielectric filler 24 having a relative dielectric constant of 2 or less, and an expansion filler 34, a coil bonding resin layer 20b, and an amine curable rubber dispersion. A stator core bonding resin layer 30a having an epoxy resin 32 and an expansion filler 34 is provided, and the coil bonding resin layer 20a and the stator core bonding resin layer 30a are bonded together on one surface. Thereby, since the expansion filler 34 is contained in the coil bonding resin layer 20b, it expands due to heat or the like together with the expansion filler 34 included in the stator core bonding resin layer 30a, and the outer peripheral surface of the coil conductor group and the resin sheet 100c. The space between the inner wall surface of the slot and the resin sheet 100c can be fixed without a gap.

  5 is provided with a heat resistant film 40 between the coil bonding resin layer 20b and the stator core bonding resin layer 30a of the resin sheet 100c shown in FIG. The coil bonding resin layer 20b is bonded to the other surface of the heat-resistant film 40 with the stator core bonding resin layer 30a. Thereby, the rigidity of the resin sheet 100d is ensured.

  Further, a resin sheet 100e shown in FIG. 6 includes a coil bonding resin layer 20c having an imide-modified unsaturated polyester resin 22, a low dielectric filler 24 having a relative dielectric constant of 2 or less, and an expansion filler 34, and an amine curable rubber dispersion. A stator core bonding resin layer 30b having an epoxy resin 32 is provided, and the coil bonding resin layer and the stator core bonding resin layer are bonded together on one surface.

Further, the resin sheet 100f shown in FIG. 7 includes a heat resistant film 40 provided between the coil joining resin layer 20c and the stator core joining resin layer 30b of the resin sheet 100e shown in FIG. The coil bonding resin layer 20c is bonded to the other surface of the heat resistant film 40 with the stator core bonding resin layer 30b. Thereby, the rigidity of the resin sheet 100f is ensured.

  Next, the structure of resin sheet 100a-100f mentioned above is demonstrated in detail.

  Since the imide-modified unsaturated polyester resin 22 of the present embodiment is crosslinked by radical polymerization, the resin fluidity is insufficient at the B stage in the middle of the curing reaction, so it is handled in the liquid A stage state when the catalyst is added. It is. However, in the A stage, since the fluidity is too high, in order to suppress excessive fluidity and stickiness and obtain adhesion with the coil conductor, the coil bonding resin layers 20a, 20b, and In 20c, a suitable type of low dielectric filler 24 is blended with the imide-modified unsaturated polyester resin 22 in a blending amount described later.

  The low dielectric filler 24 of the present embodiment is an inorganic filler having a relative dielectric constant of 2 or less. For example, calcium carbonate, talc, or a mixture of calcium carbonate and talc is used. The low dielectric filler 24 is blended in 100 ± 10 vol% with respect to 100 vol% of the imide-modified unsaturated polyester resin 22 in the coil bonding resin layers 20a, 20b, and 20c. Here, “vol%” means capacity%. When the blending amount of the low dielectric filler 24 exceeds 110 vol%, the adhesion to the coil side is deteriorated. On the other hand, when the blending amount of the low dielectric filler 24 is less than 90 vol%, the coil bonding resin layer 20a is used. , 20b, 20c, the partial discharge start voltage decreases, and the layer thickness increases.

  Here, the expansion filler is roughly classified into two types, that is, an inorganic or organic chemical expansion agent and a microcapsule physical expansion agent. Inorganic and organic chemical expansion agents are gasified by thermal decomposition and expand. There are various types of the above-mentioned two types of expansion agents, and they are manufactured by various production methods. For example, considering the effects on the curability and physical properties of the resin, the uniformity of expansion, etc., there is little contradiction. Therefore, a thermally expandable microcapsule, which is a kind of microcapsule type physical expansion agent, is preferable. In addition, a type of thermally expandable microcapsule of a microcapsule-based physical expansion agent is a microcapsule in which a liquid low-boiling substance is encapsulated with a polymer shell made of a thermoplastic polymer, and near the softening point of the polymer shell, or Vaporizes at higher temperatures and expands thermally.

  As the form of the expansion filler 34 of the present embodiment, for example, a thermally expandable microcapsule in which liquid carbon dioxide gas is sealed in a polymer shell made of a thermoplastic polymer is used, and the volume expansion is 5 times or more that of the thermally expandable microcapsule. In some cases, since the relative dielectric constant is 1.4 or less, the reduction of the dielectric constant of the resin sheet can be promoted, and the gap between the inner wall surface of the slot and the coil conductor can be reduced by the volume expansion of the resin sheet.

  In the stator core bonding resin layer 30 a when the coil bonding resin layer 20 a is used, the expansion filler 34 is blended in an amount of 1 vol% to 10 vol% with respect to 100 vol% of the amine curable rubber-dispersed epoxy resin 32. When the compounding quantity of the expansion filler 34 exceeds 10 vol%, the adhesiveness to the coil side and the stator core side is lowered, and the resin sheet itself may be brittle. On the other hand, when the blending amount of the expansion filler 34 is less than 1 vol%, thermal expansion is insufficient, and there is a high possibility that a gap is generated between the inner wall surface of the slot and the coil conductor.

Further, in the coil bonding resin layer 20 b, the expansion filler 34 is blended in an amount of 0.5 vol% to 5 vol% with respect to 100 vol% of the imide-modified unsaturated polyester resin 22. On the other hand, in the stator core bonding resin layer 30a when the coil bonding resin layer 20b is used, the expansion filler 34 is blended in an amount of 0.5 vol% to 5 vol% with respect to 100 vol% of the amine curable rubber-dispersed epoxy resin 32. The When the compounding quantity of the expansion filler 34 exceeds 5 vol%, the adhesiveness to the coil side and the stator core side is lowered, and the resin sheet itself may be brittle. On the other hand, when the blending amount of the expansion filler 34 is less than 0.5 vol%, the thermal expansion is insufficient, and there is a high possibility that a gap is generated between the inner wall surface of the slot and the coil conductor.

  Further, in the coil bonding resin layer 20 c, the expansion filler 34 is blended in an amount of 1 vol% to 10 vol% with respect to 100 vol% of the imide-modified unsaturated polyester resin 22. When the compounding quantity of the expansion filler 34 exceeds 10 vol%, adhesiveness with a coil side will fall and there exists a possibility that the resin sheet itself may also become weak. On the other hand, when the blending amount of the expansion filler 34 is less than 1 vol%, thermal expansion is insufficient, and there is a high possibility that a gap is generated between the inner wall surface of the slot and the coil conductor.

  The amine curable rubber-dispersed epoxy resin in this example is a mixture of a novolak type epoxy resin, a rubber-modified epoxy resin, a phenoxy resin, and an amine curing agent, and these four components are in consideration of adhesiveness and curing characteristics. It mix | blends suitably.

  The film thickness of the coil bonding resin layers 20a, 20b, and 20c in the present embodiment is 12 to 250 μm, and preferably 30 to 125 μm. If the film thickness of the coil bonding resin layers 20a and 20b exceeds 125 μm, the resin sheet becomes thick and the space factor of the coil conductor in the slot does not improve. On the other hand, when the film thickness of the coil bonding resin layers 20a, 20b, and 20c is less than 30 μm, a predetermined low dielectric property cannot be obtained in the coil bonding resin layers 20a, 20b, and 20c.

  The film thickness of the stator core bonding resin layers 30a and 30b in the present embodiment is 12 to 250 μm, and preferably 30 to 125 μm. If the film thickness of the stator core bonding resin layers 30a and 30b exceeds 125 μm, the film thickness of the resin sheet increases, and the space factor of the coil conductor in the slot does not improve. On the other hand, when the film thickness of the stator core bonding resin layers 30a and 30b is less than 30 μm, the adhesion between the stator core bonding resin layers 30a and 30b and the inner wall surface of the slot is likely to deteriorate.

  Examples of the heat-resistant film in the present embodiment include polyethylene naphthalate resin (PEN), polyphenylene sulfide resin (PPS), polyether ether ketone resin (PEEK), liquid crystal polymer (Liquid Crystal Polymer, LCP), aramid paper (Nomec) Paper), LPC paper and the like are used. The thickness of the heat-resistant film in the present embodiment is 12 to 250 μm, preferably 50 to 125 μm. If the thickness of the heat-resistant film exceeds 125 μm, the resin sheet becomes thick and the space factor of the coil conductor in the slot does not improve. On the other hand, when the thickness of the heat-resistant film is less than 12 μm, the resin sheet is not given rigidity.

[Motor stator]
As shown in FIG. 8, the motor stator according to the present embodiment accommodates a coil conductor group formed by insulating a plurality of coil conductors 52 in slots in the stator core 10. And it has the stator core 10 provided with the some slot, the coil conductor group accommodated in a slot, and the insulating resin sheet 100 for coil fixation which covers the outer peripheral surface of a coil conductor group. The coil fixing insulating resin sheet 100 is any one of the resin sheets 100a to 100f described above, and the outer peripheral surface of the coil conductor group formed by insulating between the coil conductors 52 and the coil fixing insulating resin. The coil bonding resin layer of the sheet 100 is in contact, and the inner wall of the slot and the stator core bonding resin layer of the coil fixing insulating resin sheet 100 are in contact.

  In the stator 200 of the present embodiment having the above configuration, the coil conductor space factor in the slot exceeds about 60%. In general, considering that the motor output changes greatly only by increasing the coil conductor space factor in the slot by 1 to 2%, this is about 50% of the coil wire space factor in the slot in the conventional starter. It can be seen that it is much higher than%.

[Method for manufacturing motor stator]
As an example of a method for manufacturing a motor stator according to the present embodiment, examples of four manufacturing methods will be described below with reference to FIGS.

  First, an example of the first manufacturing method will be described with reference to FIG. When the coil bonding resin layer of the coil fixing insulating resin sheet 100 made of any one of the resin sheets 100a to 100f described above is in a semi-cured state or a liquid state having fluidity, the coil conductors are insulated. The coil fixing insulating resin sheet 100 is wound around the outer periphery of the coil conductor group so as to be in contact with the outer peripheral surface of the coil conductor group 50 thus formed, thereby forming a temporary coil assembly 60a. Next, the temporary coil assembly 60a is inserted into the slot 11 of the stator core. Next, after inserting the coil temporary assembly 60a into the slot between the teeth 1 and 2, the coil fixing insulating resin sheet 100 is expanded and cured by heating, and the outer peripheral surface of the coil conductor group 50 and the coil are fixed. The insulating resin sheet 100 for fixing and the inner wall surface of the slot 11 and the insulating resin sheet 100 for fixing the coil are fixed.

  According to the first manufacturing method, the coil temporary insulating assembly 60a is formed by winding the coil fixing insulating resin sheet 100 around the outer periphery of the coil conductor group 50 formed by insulating a plurality of coil conductors in advance. Therefore, it can be easily inserted into the slot 11 and the assembly efficiency is improved.

  Next, an example of the second manufacturing method will be described with reference to FIG. When the coil bonding resin layer of the coil fixing insulating resin sheet 100 made of any one of the resin sheets 100a to 100f described above is in a semi-cured state or a liquid state having fluidity, the coil conductors are insulated. Then, the coil conductor group is fitted into the coil fixing insulating resin sheet 100 so as to be in contact with the outer peripheral surface of the coil conductor group 50 thus formed, thereby forming the temporary coil assembly 60b. Next, the temporary coil assembly 60b is inserted into the slot 11 of the stator core. Next, after inserting the coil temporary assembly 60b into the slot between the teeth 1 and 2, the coil fixing insulating resin sheet 100 is expanded and cured by heating, and the outer peripheral surface of the coil conductor group 50 and the coil are fixed. The insulating resin sheet 100 for fixing and the inner wall surface of the slot 11 and the insulating resin sheet 100 for fixing the coil are fixed.

  According to the example of the second manufacturing method, as compared with the example of the first manufacturing method, only the coil conductor group 50 is fitted into the coil fixing insulating resin sheet 100, and the assembly efficiency is further improved.

Furthermore, an example of the third manufacturing method will be described with reference to FIG. Coil fixing is performed in advance so that the stator core bonding resin layer of the coil fixing insulating resin sheet 100 made of any one of the resin sheets 100a to 100f contacts the inner wall surface of the slot 11 of the stator core in a semi-cured state. The insulating resin sheet 100 is bent into a slot shape. Next, the coil fixing insulating resin sheet 100 bent into a slot shape is inserted into the slot 11. Next, the coil conductor group 50 formed by insulating a plurality of coil conductors is brought into contact with the coil-bonding resin layer of the coil-fixing insulating resin sheet 100 in a semi-cured state or in a liquid state having fluidity. After inserting the coil conductor group 50 into the slot between the teeth 1 and 2, the coil fixing insulating resin sheet 100 is heated and expanded and cured, and the outer peripheral surface of the coil conductor group 50 and the coil are fixed. Insulating resin sheet 100
And between the inner wall surface of the slot 11 and the insulating resin sheet 100 for fixing the coil.

  According to the third example of the manufacturing method, since the coil fixing insulating resin sheet 100 is previously bent into a slot shape and inserted into the slot, the coil fixing insulating resin sheet 100 is securely inserted into the slot 11. Positioned. Further, since the coil conductor group 50 is inserted using the inserted coil fixing insulating resin sheet 100 as a guide, the coil conductor group 50 is inserted between the inner wall surface of the slot 11 and the coil fixing insulating resin sheet 100 at the time of insertion of the coil conductor group. The gap between the outer peripheral surface of the conductor group 50 and the coil fixing insulating resin sheet 100 is significantly reduced.

  An example of the fourth manufacturing method will be described with reference to FIG. In the example of the third manufacturing method, cuff portions 70a and 70b are provided at both ends of a coil fixing insulating resin sheet 100 (described in FIG. 9) that is bent into a slot shape. The cuff portions 70a and 70b prevent the coil fixing insulating resin sheet 100 from coming out of the slot.

  EXAMPLES Hereinafter, although an Example demonstrates this invention further in detail, this invention is not limited by these.

[Example 1]
In the structure of the structural resin sheet in FIG. 2, a coil bonding resin layer of the resin sheet was prepared according to the blending amount shown in Table 1, and the performance evaluation of the coil bonding resin layer of the obtained resin sheet was performed. The results are shown in Table 1.

Ii) * 1: In consideration of the stickiness of the coil-bonding resin layer, “○” is indicated when the workability is good, and “X” is indicated when the workability is poor.
* 2: The relative dielectric constant is a theoretical value.
* 3: As for the adhesion strength, the tensile strength was measured in accordance with JIS K 6251 at two temperatures of 20 ° C. and 180 ° C. for the adhesion strength of the coil-bonded resin layer after curing. The case where both measured values at two temperatures were 0.6 MPa or more was “◯”, and the case where at least one of the two temperatures was less than 0.6 MPa was “x”. In Table 2 and later, the fixing strength of the stator core bonding resin layer to the slot after curing was evaluated in the same manner as described above.

  Furthermore, with respect to the coil bonding resin layer having the composition ratio of Experimental Example 4 shown in Table 1, a stator core bonding resin layer of a resin sheet is prepared with the blending amount shown in Table 2, and the stator core bonding resin layer of the obtained resin sheet is prepared. The performance evaluation was performed. The results are shown in Table 2.

Ii) * 4: The fillability of the gap between the slot and the coil conductor is determined based on the maximum gap between the slot and the coil conductor before expansion due to the heat of the resin sheet, and if the maximum gap is less than 0.3 mm. Since it was possible to ensure the filling property, “◯” was given, and when it was 0.3 mm or more, the filling property could not be secured, and “X” was given.
* 5: The brittleness of the resin sheet is evaluated with respect to the appearance after expansion. When the resin expands too much and peels off when the resin is touched by hand, “X” is indicated. On the other hand, when it does not peel off, “○” indicates. It was.

[Example 2]
In the structure of the structural resin sheet of FIG. 4, based on the composition ratio of Experimental Example 4 shown in Table 1, an expansion filler is blended in the blending amount shown in Table 3, and a coil bonding resin layer of the resin sheet is prepared and obtained. The performance of the coil-bonded resin layer of the resin sheet was evaluated. The results are shown in Table 3.

  Furthermore, with respect to the coil bonding resin layer having the composition of Experimental Example 14 shown in Table 3, a stator core bonding resin layer of the resin sheet was prepared with the blending amount shown in Table 4, and the stator core bonding resin layer of the obtained resin sheet Performance evaluation was performed. The results are shown in Table 4.

[Example 3]
In the structure of the structural resin sheet in FIG. 6, based on the composition ratio of Experimental Example 4 shown in Table 1, an expansion filler was blended in a blending amount shown in Table 3 to prepare a coil bonding resin layer of the resin sheet. The performance evaluation of the coil bonding resin layer of the obtained resin sheet is as shown in Table 3 above.

  Furthermore, with respect to the coil bonding resin layers having the compositions of Experimental Examples 17 to 21 shown in Table 3, a stator core bonding resin layer of a resin sheet was prepared with a blending amount shown in Table 6, and the obtained stator core bonding resin of the resin sheet The performance of the layer was evaluated. The results are shown in Table 5.

  Further, when the resin sheet composed of the resin layer for coil bonding of Experimental Example 4 and the resin layer for stator core bonding of Experimental Example 9 was used, the space factor of the coil conductor in the slot was 63%. In addition, in Example 7 described in Table 2, Example 12 described in Table 3, Example 17 described in Table 4, and Example 22 described in Table 5, since no expansion filler was contained, filling Sex is “x”.

  The present invention is effective for any application as long as it is used for manufacturing a stator for a motor.

1-6 teeth, 10 stator core, 10A end face, 11-18 slots, 20a, 20b, 20c coil bonding resin layer, 22 imide-modified unsaturated polyester resin, 24 low dielectric filler, 30a, 30b stator core bonding resin layer, 32 Amine curable rubber dispersed epoxy resin, 34 expansion filler, 40 heat resistant film, 50 coil conductor group, 52 coil conductor, 60a, 60b coil temporary assembly, 100 insulating resin sheet for fixing coil, 100a-100f resin sheet, 200 for motor Stator.

Claims (8)

A coil bonding resin layer having an imide-modified unsaturated polyester resin and a low dielectric filler having a relative dielectric constant of 2 or less;
A stator core bonding resin layer comprising an amine curable rubber-dispersed epoxy resin and an expansion filler;
The has the low dielectric filler viewing contains a mixture of calcium carbonate and talc, wherein the amine-curable rubber-dispersed epoxy resin, novolak type epoxy resins, rubber-modified epoxy resins, phenoxy resins, and a mixture of amine curing agent coil fixing insulating resin sheet, characterized in that. In the insulating resin sheet for fixing a coil according to claim 1,
The coil-bonding insulating resin sheet, wherein the coil-bonding resin layer further contains an expansion filler. In the insulating resin sheet for fixing a coil according to claim 1 or 2,
A heat-resistant film is provided between the coil bonding resin layer and the stator core bonding resin layer. A coil bonding resin layer comprising an imide-modified unsaturated polyester resin, a low dielectric filler having a relative dielectric constant of 2 or less, and an expansion filler;
A stator core bonding resin layer having an amine curable rubber dispersed epoxy resin;
The has the low dielectric filler viewing contains a mixture of calcium carbonate and talc, wherein the amine-curable rubber-dispersed epoxy resin, novolak type epoxy resins, rubber-modified epoxy resins, phenoxy resins, and a mixture of amine curing agent coil fixing insulating resin sheet, characterized in that. A stator for a motor in which a coil conductor group formed by insulating between a plurality of coil conductors is accommodated in a slot in a stator core,
A stator core provided with a plurality of slots;
A coil conductor group housed in the slot;
A coil fixing insulating resin sheet covering the outer peripheral surface of the coil conductor group,
The coil fixing insulating resin sheet is the coil fixing insulating resin sheet according to any one of claims 1 to 4, wherein an outer peripheral surface of a coil conductor group and the coil bonding resin layer are in contact with each other. A coil fixing insulating resin, wherein an inner wall of the slot and the stator core bonding resin layer are arranged to contact each other, and the expansion filler in the coil fixing insulating resin sheet is in a thermally expanded state. A stator for a motor using a sheet. The coil bonding resin layer of the insulating resin sheet for fixing a coil according to any one of claims 1 to 4 is in contact with an outer peripheral surface of a coil conductor group formed by insulating a plurality of coil conductors. The coil fixing insulating resin sheet is wound around the outer periphery of the coil conductor group to form a temporary coil assembly,
Inserting the coil temporary assembly into a slot of the stator core;
The coil fixing insulating resin sheet is expanded and cured by heating, and the coil conductor group is fixed between the outer peripheral surface of the coil conductor group and the coil fixing insulating resin sheet and between the inner wall surface of the slot and the coil fixing insulating resin sheet. A method for manufacturing a stator for a motor. The coil bonding resin layer of the insulating resin sheet for fixing a coil according to any one of claims 1 to 4 is in contact with an outer peripheral surface of a coil conductor group formed by insulating a plurality of coil conductors. A coil conductor group is fitted into the insulating resin sheet for fixing the coil to form a temporary coil assembly,
Inserting the coil temporary assembly into a slot of the stator core;
The coil fixing insulating resin sheet is expanded and cured by heating, and the coil conductor group is fixed between the outer peripheral surface of the coil conductor group and the coil fixing insulating resin sheet and between the inner wall surface of the slot and the coil fixing insulating resin sheet. A method for manufacturing a stator for a motor. The coil fixing insulating resin sheet is previously slotted so that the stator core bonding resin layer of the coil fixing insulating resin sheet according to any one of claims 1 to 4 is in contact with an inner wall surface of the stator core slot. Bend into shape and insert into slot,
A coil conductor group formed by insulating between a plurality of coil conductors is inserted so as to be in contact with the coil bonding resin layer of the coil fixing insulating resin sheet,
The coil fixing insulating resin sheet is expanded and cured by heating, and the coil conductor group is fixed between the outer peripheral surface of the coil conductor group and the coil fixing insulating resin sheet and between the inner wall surface of the slot and the coil fixing insulating resin sheet. A method for manufacturing a stator for a motor.

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