WO2024176761A1

WO2024176761A1 - Stator and motor using same

Info

Publication number: WO2024176761A1
Application number: PCT/JP2024/003115
Authority: WO
Inventors: 洸太郎森
Original assignee: パナソニックＩｐマネジメント株式会社
Priority date: 2023-02-22
Filing date: 2024-01-31
Publication date: 2024-08-29
Also published as: JP2024119643A

Abstract

A stator (2) comprises: a stator core (8) that has a plurality of tooth parts (41) that protrude toward the outside in the radial direction from the outer circumferential surface of a cylinder and slots (42) that are formed between adjacent tooth parts; and a pair of insulators (20) that sandwich the plurality of tooth parts (41) from respective sides in the axial direction of the cylinder. The insulators (20) comprise: a base part (21) that is formed at a surface orthogonal to the axial direction and abuts an end of the stator core (8) in the axial direction; and wall parts (22) that extend from the base part in the axial direction along inner walls of the slots (42). The wall parts (22) comprise: an inner layer part (23) that has a positive slope surface (25) at which the height from the base part (21) increases at a slope of a prescribed angle from one side to the other side of the adjacent tooth parts (41) that form the inner wall of the respective slot (42); and an outer layer part (24) that is positioned between the outer perimeter of the inner layer part (23) and the inner wall of the respective slot (42) and has a negative slope surface (26) at which the height from the base part (21) decreases at a slope of a prescribed angle from one side to the other side.

Description

Stator and motor using same

This disclosure relates to a stator and a motor using the same.

　Conventionally, electric motors are known in which a stator is placed on the outer or inner circumference of a rotor to which a magnet is attached. In the stator of such an electric motor, coils are attached via insulators to salient poles formed on the inner or outer circumference of a roughly cylindrical stator core.

For example, Patent Document 1 discloses annular insulators A101 and B201 that are attached to a stator core having salient poles by sandwiching them from both axial sides as shown in Figures 7A and 7B. The insulator A101 has a substantially cylindrical first wall portion 103 extending axially from the base portion 102, and the insulator B201 has a substantially cylindrical second wall portion 203 extending axially from the base portion 202. The insulators also have a first protrusion portion 204 that thickens the second wall portion 203 over the entire circumference of the second wall portion 203. When attached to the stator core, the first protrusion portion 204 abuts against the wall surface of the salient pole. Furthermore, the first wall portion 103 is located between the second wall portion 203 and the wall surface of the salient pole, and the first wall portion 103 and the second wall portion 203 overlap by a predetermined dimension.

Patent No. 6484824

In this way, conventionally, wall portions extending from a pair of insulators overlap each other along the wall surfaces of the salient poles, ensuring insulation between the coil and the stator core. However, in conventional shapes, the shapes of the walls of one insulator and the other insulator are different in order to overlap one wall portion with the other wall portion. For example, in Patent Document 1, a first protrusion 204 is provided around the entire circumference of the second wall portion 203 in order to position the first wall portion 103 between the second wall portion 203 and the wall surface of the salient pole. Therefore, when machining a pair of insulators, different dies are required for one insulator and the other insulator, leaving room for improvement in productivity.

The purpose of this disclosure is to provide a stator that has an insulator that is highly manufacturable and provides high insulation between the stator core and the coil.

In order to achieve the above object, the stator according to the present disclosure comprises a stator core having a plurality of teeth protruding radially outward from the outer peripheral surface of the cylinder and slots formed between adjacent teeth, and a pair of insulators sandwiching the plurality of teeth from both sides in the axial direction of the cylinder, the insulator being composed of surfaces perpendicular to the axial direction and comprising a base abutting the axial end of the stator core and a wall extending in the axial direction from the base along the inner wall of the slot, the wall comprising an inner layer having a positive inclined surface whose height from the base increases at a predetermined angle from one side to the other of adjacent teeth forming the inner wall of the slot, and an outer layer having a reverse inclined surface whose height from the base decreases at a predetermined angle from one side to the other, thereby achieving the intended object.

The present disclosure can provide a stator that has an insulator that is highly manufacturable and provides high insulation between the stator core and the coil.

FIG. 2 is a cross-sectional view showing the internal configuration of a motor according to the present disclosure. 1 is a schematic diagram showing a configuration of a stator according to the present disclosure. FIG. 2 is an exploded perspective view of a stator according to the present disclosure. 1A and 1B are a perspective view and a partially enlarged view of an insulator according to the present disclosure. FIG. 4 is a partial enlarged view of a wall portion according to the present disclosure. FIG. 13 is a top view showing a wall portion according to the present disclosure inserted into a slot. 11A to 11C are schematic diagrams showing a procedure for inserting a wall portion 22a into a slot as a procedure for mounting an insulator according to the present disclosure. 13A to 13C are schematic diagrams showing a procedure for inserting a wall portion 22b into a slot as a procedure for mounting an insulator according to the present disclosure. 5A and 5B show wall portions 22a and 22b overlapping inside the slot according to the present disclosure. FIG. FIG. 13 is a schematic diagram of a structure in which an inner low wall is directly connected to an inner high wall, and an outer low wall is directly connected to an outer high wall, as an example showing the effect of the positive inclined surface according to the present disclosure. FIG. 13 is a schematic diagram of a structure in which the height is continuously changed by providing an inner layer inclined wall and an outer layer inclined wall, as an example showing the effect of the positive inclined surface according to the present disclosure. FIG. 2 is a perspective view of an insulator mounted on a stator of Patent Document 1. FIG. 2 is a perspective view of an insulator mounted on a stator of Patent Document 1.

Below, an embodiment of the present disclosure will be described with reference to the drawings. Note that the embodiment below is an example of a concrete embodiment of the present disclosure, and does not limit the technical scope of the present disclosure. Furthermore, the same parts are given the same reference numerals throughout the drawings, and descriptions thereof will be omitted from the second and subsequent drawings. Furthermore, detailed descriptions of each part that is not directly related to the present disclosure will be omitted in each drawing.

(Embodiment)
A motor according to the present disclosure will be described with reference to Fig. 1. Fig. 1 is a cross-sectional view showing the internal configuration of motor 1. Hereinafter, a direction parallel to the rotation axis of motor 1 will be referred to as the "axial direction", and a direction perpendicular to the axial direction will be referred to as the "radial direction". In addition, with regard to the radial direction, a direction away from the rotation axis will be referred to as the "radial outer direction", and a direction approaching the rotation axis will be referred to as the "radial inner direction".

The motor 1 includes a stator 2, a rotor yoke 3, a rotor cover 4, a shaft 5, and a bearing 6.

The stator 2 generates a magnetic flux when supplied with current from the outside, causing the rotor yoke 3 to rotate. Details of the stator 2 will be described later.

The rotor yoke 3 is cylindrical with an opening on the bottom side, and contains the stator 2 inside the cylindrical shape. In other words, the rotor yoke 3 surrounds the outer periphery of the stator 2 in an annular shape with a uniform spatial gap. The rotor yoke 3 includes a magnet 7, a housing 14a, and an upper shaft opening 12.

The magnets 7 generate torque to rotate the rotor yoke 3 by receiving the magnetic flux generated by the stator 2. Multiple magnets 7 are provided at predetermined intervals around the circumferential direction on the inner surface of the cylindrical rotor yoke 3.

The housing 14a is cylindrical and has a space inside for holding the bearing 6. The housing 14a protrudes axially outward from the center of the rotor yoke 3.

The upper shaft opening 12 is located at the center of the top surface of the cylindrical shape. In other words, the upper shaft opening 12 is located at the center of the housing 14a.

The rotor cover 4 covers the opening on the bottom side of the rotor yoke 3. The rotor cover 4 is, for example, provided in a roughly circular shape that is larger than the opening on the bottom side of the rotor yoke 3. The rotor cover 4 includes a housing 14b and a lower shaft opening 13.

Housing 14b is cylindrical and has a space inside for holding bearing 6. Housing 14b protrudes axially outward from the center of rotor cover 4. Housing 14b has the same inner diameter as housing 14a.

The lower shaft opening 13 is provided at the center of the approximately circular shape of the rotor cover 4. In other words, the lower shaft opening 13 is provided at the center of the housing 14b.

The shaft 5 is cylindrical. The shaft 5 is inserted through the upper shaft opening 12 and the lower shaft opening 13 and fixed to the center of the stator 2. The central axis of the cylindrical shaft 5 is aligned in the same line as the rotation axis of the motor 1.

The bearing 6 holds the shaft 5 so that it can rotate freely. The bearing 6 is a hollow cylinder with an outer diameter equal to the inner diameter of the housings 14a and 14b. The shaft 5 is inserted into the inside of the hollow cylinder. The bearings 6 are provided in a pair and are positioned so as to sandwich the stator 2 in the axial direction. Specifically, one of the pair, the bearing 6a, is press-fitted and fixed to the shaft 5 on the axially upper side of the stator 2, and the other bearing 6b is press-fitted and fixed to the shaft 5 on the axially lower side of the stator 2. In other words, the inner circumferential surface of one bearing 6a is held on the outside of the shaft 5, and the inner circumferential surface of the other bearing 6b is held on the outside of the shaft 5.

The motor 1 configured in this way rotates the rotor yoke 3 and rotor cover 4 around the shaft 5 in response to the magnetic flux generated by the stator 2. In other words, the motor 1 is an outer rotor type motor.

Next, the stator 2 according to this embodiment will be described with reference to Figures 2 and 3. Figure 2 is a schematic diagram showing the configuration of the stator 2. Figure 3 is an exploded perspective view of the stator 2.

The stator 2 includes a stator core 8, terminals 10, a substrate 9, a coil 11, and an insulator 20.

The stator core 8 is formed into a generally cylindrical shape by stacking multiple roughly disk-shaped steel plates in the axial direction. The stator core 8 has a cylindrical portion 43, a central hole 40, teeth 41, and slots 42.

The cylindrical portion 43 is the inner peripheral portion that constitutes the roughly cylindrical shape of the stator core 8.

The central hole 40 is a through hole for inserting the shaft 5 and is provided at the center of the stator core 8. In other words, the central hole 40 is provided at the center of the cylindrical portion 43.

The tooth portion 41 is a protruding portion for winding the coil 11 around the stator core 8. The tooth portion 41 protrudes radially outward from the outer circumferential surface of the cylindrical portion 43. A plurality of tooth portions 41 are provided at equal intervals around the circumference of the cylindrical portion 43. In other words, the tooth portions 41 are provided radially on the outer circumferential side of the cylindrical portion 43. The number of tooth portions 41 may be freely changed depending on the specifications of the motor 1. The tooth portion 41 includes a winding portion 44 and a curved portion 45.

The winding portion 44 connects the cylindrical portion 43 and the curved portion 45. The coil 11 is wound around the winding portion 44 via the insulator 20.

The curved surface portion 45 increases the surface area of the stator core 8 in the circumferential direction, thereby increasing the area that receives the magnetic flux generated by the magnet 7. In other words, the curved surface portion 45 allows the stator core 8 to efficiently receive the magnetic flux from the magnet 7. The curved surface portion 45 is arranged to extend from the radially outer end of the winding portion 44 to both sides in the circumferential direction relative to the rotating shaft of the motor 1 by the same length.

The slot 42 is a space for winding the coil 11 around the tooth portion 41. The slot 42 is formed with the outer peripheral surface of the cylindrical portion 43 and the side surface of the adjacent tooth portion 41 as inner walls. The slot 42 is a space having a thickness of h0 in the axial direction. Here, h0 is equal to the axial thickness of the stator core 8.

The terminal 10 is installed at the axial end of the cylindrical portion 43 of the stator core 8. The terminal 10 is formed in a disk shape. The terminal 10 supports a jumper wire for electrically connecting the coils 11 to each other on the opposite side of the terminal 10 from the stator core 8. With this configuration, the terminal 10 maintains insulation between the jumper wire and the stator core 8.

The circuit board 9 is installed on the side opposite the side facing the stator core of the terminal 10. The circuit board 9 controls the flow of current through a drive circuit board installed outside the motor 1, and supplies current to the coil 11.

The coil 11 is a conductive wire whose main material is an alloy of copper and aluminum. The coil 11 is wound around the stator core 8 via the insulator 20, and generates magnetic flux when electricity is passed through it.

The insulators 20 are installed in pairs at both axial ends of the tooth portion 41 of the stator core 8. The insulators 20 are provided in an annular shape and are attached by sandwiching the stator core 8 from both axial sides as shown in FIG. 3. The insulators 20 are made of, for example, a resin molded product. By winding the coil 11 through the insulator 20, insulation between the stator core 8 and the coil 11 is ensured. The insulator 20 has a base 21 and a wall portion 22.

The base 21 is formed in an annular shape having a surface perpendicular to the axial direction. The base 21 is provided in contact with the axial end face of the stator core 8 and is positioned so as to cover the tooth portion 41.

The wall portion 22 is formed in a cylindrical shape extending axially inward from the base portion 21. The wall portion 22 extends along the inner wall of the slot 42. In other words, the wall portion 22 extends along the side surface of the tooth portion 41 and the outer peripheral surface of the cylindrical portion 43.

Next, the structure of the insulator 20 will be described in more detail with reference to Figures 4A to 4C. Figure 4A is a perspective view of the insulator 20. Figure 4B is a partially enlarged view of the wall portion 22. Figure 4C is a top view showing the wall portion 22 inserted into the slot 42. In the following description, to explain the shape of the wall portion 22 in detail, the left side of the adjacent tooth portions 41 that form the slot 42 in Figure 4C will be referred to as one tooth portion 41a and the right side as the other tooth portion 41b.

In addition, in FIG. 4B, a wall midline 33 is provided as a virtual line for explaining the wall 22. The wall midline 33 is a straight line parallel to the axis and is provided at a position that bisects the wall 22 into one tooth portion 41a side and the other tooth portion 41b side. The wall midline 33 is provided along the inner layer inclined wall 31 and the outer layer inclined wall 32, which will be described later.

The wall portion 22 includes a winding opening 35, a winding locking portion 36, an inner layer portion 23, and an outer layer portion 24.

The winding opening 35 is an opening provided to pass the coil 11 from the radially outer side. The winding opening 35 is provided by cutting out a part of the cylindrical wall portion 22 radially outward.

The winding locking portion 36 is a protrusion that prevents the coil 11 from moving radially outward through the winding opening 35 after it has been wound around the tooth portion 41. The winding locking portion 36 also serves to provide a physical distance between the tip of the curved portion 45 and the coil 11 and improve insulation by locking the coil 11 closer to the tooth portion 41 than to the winding opening 35. The winding locking portion 36 protrudes radially inward from both ends of the wall portion 22 that forms the winding opening 35.

The inner layer portion 23 is a wall surface that constitutes the inner peripheral side of the wall portion 22. The inner layer portion 23 is provided on the opposite side of the inner wall of the slot 42, sandwiching the outer layer portion 24. In other words, the outer peripheral surface of the inner layer portion 23 abuts against the inner peripheral surface of the outer layer portion 24. The inner layer portion 23 includes an inner layer high wall 29, an inner layer low wall 27, an inner layer inclined wall 31, and a positive inclined surface 25.

The inner layer low wall 27 is the wall surface that has the lowest height from the base 21 in the inner layer portion 23. The inner layer low wall 27 protrudes in the axial direction from the base 21 along one of the adjacent tooth portions 41a. The inner layer low wall 27 includes a wall surface that protrudes in the axial direction along one of the winding portions 44a and a wall surface that protrudes in the axial direction along one of the curved portions 45a, and is provided in a generally L-shape when viewed from above (see FIG. 4C). The protruding tip of the inner layer low wall 27 protrudes to a position where the height from the base 21 is h1. h1 is, for example, a value smaller than half the axial thickness h0 of the stator core 8.

The inner layer high wall 29 is the wall surface that is the highest from the base 21 in the inner layer portion 23. The inner layer high wall 29 protrudes in the axial direction from the base 21 along the other tooth portion 41b of the adjacent tooth portions 41. The inner layer high wall 29 includes a wall surface that protrudes in the axial direction along the other winding portion 44b and a wall surface that protrudes in the axial direction along the other curved surface portion 45b, and is provided in a generally inverted L shape when viewed from above (see FIG. 4C). The protruding tip of the inner layer high wall 29 protrudes to a position where the height from the base 21 is h2. h2 is, for example, smaller than h0, which is the axial thickness of the stator core 8, and is greater than half of h0.

The inner layer inclined wall 31 is located between the inner layer low wall 27 and the inner layer high wall 29, and protrudes axially from the base 21 along the outer circumferential surface of the cylindrical portion 43. In other words, the inner layer inclined wall 31 is adjacent to the inner layer low wall 27 and the inner layer high wall 29. The inner layer inclined wall 31 has a lowest part that abuts against the inner layer low wall 27 and has the lowest height from the base 21 in the inner layer portion 23, and a highest part that abuts against the inner layer high wall 29 and has the highest height from the base 21. Here, the height of the lowest part is h1, which is equal to the inner layer low wall 27, and the height of the highest part is h2, which is equal to the inner layer high wall 29. It also has a middle part whose height from the base 21 is h3, which is halfway between the lowest part and the highest part.

The height of the inner layer inclined wall 31 increases continuously at a predetermined angle from one tooth portion 41a side to the other tooth portion 41b side. Continuously means that there is no step. The height of the inner layer inclined wall 31 is h1 at the lowest part that contacts the inner layer low wall 27, and gradually increases as it approaches the other tooth portion 41b. In addition, when it passes the position of the wall midline 33, it reaches a height h3 that is halfway between the lowest part and the highest part (middle part). Furthermore, the height reaches h2 at the highest part that contacts the inner layer high wall 29.

The positive inclined surface 25 is a slope formed at the protruding tip of the inner layer inclined wall 31. The positive inclined surface 25 becomes continuously higher at a predetermined angle from one tooth portion 41a side to the other tooth portion 41b side. The positive inclined surface 25 connects the protruding tip of the inner layer low wall 27 and the protruding tip of the inner layer high wall 29.

The outer layer portion 24 is a wall surface that constitutes the outer peripheral side of the wall portion 22. The outer layer portion 24 is located on the outer peripheral side of the inner layer portion 23, and is located between the inner layer portion 23 and the inner wall of the slot 42 when inserted into the slot 42. In other words, the outer peripheral surface of the outer layer portion 24 abuts against the inner wall of the slot 42, and the inner peripheral surface abuts against the outer peripheral surface of the inner layer portion 23. The outer layer portion 24 comprises an outer layer high wall 30, an outer layer low wall 28, an outer layer inclined wall 32, a counter-inclined surface 26, and a protrusion portion 34.

The outer layer low wall 28 is the wall surface in the outer layer portion 24 that has the lowest height from the base 21. The outer layer low wall 28 protrudes axially from the base 21 along the other tooth portion 41b of the adjacent tooth portions 41. The outer layer low wall 28 includes a wall surface that protrudes axially along the other winding portion 44b and a wall surface that protrudes axially along the other curved surface portion 45b, and is provided in a generally inverted L shape when viewed from above (see FIG. 4C). The protruding tip of the outer layer low wall 28 protrudes to a position where the height from the base 21 is h1.

The outer layer high wall 30 is the wall surface in the outer layer portion 24 that has the highest height from the base portion 21. The outer layer high wall 30 protrudes in the axial direction from the base portion 21 along one of the adjacent tooth portions 41a. The outer layer high wall 30 includes a wall surface that protrudes in the axial direction along one of the winding portions 44a and a wall surface that protrudes in the axial direction along one of the curved portions 45a, and is provided in a substantially L-shape when viewed from above (see FIG. 4C). The protruding tip of the outer layer high wall 30 protrudes to a position where the height from the base portion 21 is h2.

The outer layer inclined wall 32 is located between the outer layer low wall 28 and the outer layer high wall 30, and protrudes axially from the base 21 along the outer peripheral surface of the cylindrical portion 43. In other words, the outer layer inclined wall 32 is adjacent to the outer layer low wall 28 and the outer layer high wall 30. The outer layer inclined wall 32 has a lowest part that abuts against the outer layer low wall 28 and has the lowest height from the base 21 in the outer layer portion 24, and a highest part that abuts against the outer layer high wall 30 and has the highest height from the base 21. Here, the height of the lowest part is h1, which is the same as the inner layer low wall 27 and the outer layer low wall 28, and the height of the highest part is h2, which is the same as the inner layer high wall 29 and the outer layer high wall 30. It also has a middle part whose height from the base 21 is h3, which is intermediate between the lowest part and the highest part.

The height of the outer layer inclined wall 32 decreases continuously at a predetermined angle from one tooth portion 41a side to the other tooth portion 41b side. The height of the outer layer inclined wall 32 is h2 at the highest portion that contacts the outer layer high wall 30, and gradually decreases as it approaches the other tooth portion 41b. In addition, when passing through the position of the wall portion midline 33, it reaches a height h3 that is halfway between the lowest portion and the highest portion (middle portion). Furthermore, the height reaches h1 at the lowest portion that contacts the outer layer low wall 28.

In this way, the wall 22 has a cross-shaped structure in which the height of the inner layer 23 and the height of the outer layer 24 are switched at the wall midline 33. Furthermore, the inner high wall 29 has the same height as the outer high wall 30, and the inner low wall 27 has the same height as the outer low wall 28. In other words, the height of the inner layer 23 and the height of the outer layer 24 are linearly symmetrical with the wall midline as the axis of symmetry.

The counter-inclined surface 26 is a slope formed at the protruding tip of the outer layer inclined wall 32. The counter-inclined surface 26 becomes continuously lower at a predetermined angle from one tooth portion 41a side to the other tooth portion 41b side. The counter-inclined surface 26 connects the protruding tip of the outer layer low wall 28 and the protruding tip of the outer layer high wall 30.

The protrusion 34 is a protrusion that protrudes radially inward on the wall midline 33 of the outer layer inclined wall 32. In other words, it protrudes from the outer layer inclined wall 32 toward the outer periphery beyond the wall 22. The tip of the protrusion 34 abuts against the outer peripheral surface of the cylindrical portion 43, ensuring a physical distance between the wall 22 and the cylindrical portion 43. This configuration can further ensure insulation between the coil 11 and the stator core 8. It can also assist in positioning the insulator 20 relative to the stator core 8 when inserting the wall 22 into the slot 42.

Next, referring to Figures 5A to 5C, the movement when the wall portions 22 of a pair of insulators 20 are overlapped from both axial sides will be described in detail. For the sake of explanation, the insulator arranged on the lower side in Figures 5A to 5C will be referred to as insulator 20a, and the insulator arranged on the upper side will be referred to as insulator 20b. Note that insulators 20a and 20b have the same shape. Other components such as the inner layer portion 23 and outer layer portion 24 will also be described by adding the letter a to those arranged on the lower side and the letter b to those arranged on the upper side.

Figures 5A to 5C are schematic diagrams seen from the radial inside showing the procedure for placing the insulator 20 on the stator core 8. Figure 5A shows the procedure for inserting wall portion 22a into slot 42. Figure 5B shows the procedure for inserting wall portion 22b into slot 42. Figure 5C shows the state of wall portion 22a and wall portion 22b overlapped inside slot 42 in Figures 5A and 5B. Note that the inner layer portion 23 hidden behind the outer layer portion 24 in Figure 5B is indicated by a dashed line.

First, we will explain how to place the insulator 20a with reference to Figure 5A.

First, the outer layer high-level wall 30a is inserted into the slot 42. At this time, the outer peripheral surface of the outer layer high-level wall 30a is slid against the side surface of one of the teeth 41a that constitutes the inner wall of the slot 42, making it easy to position the insulator 20a relative to the stator core 8.

Next, the outer wall of the outer layer lower wall 28a is slid against the side of the other tooth portion 41b and further inserted, and the base 21a is abutted against one end of the stator core 8. This procedure allows the insulator 20a to be placed on one end of the stator core 8.

Next, the placement of the insulator 20b will be described with reference to FIG. 5B. In FIG. 5B, the insulator 20a has already been placed on one end of the stator core 8 by the procedure in FIG. 5A.

First, the outer layer high-level wall 30b is inserted into the slot 42. At this time, the outer peripheral surface of the outer layer high-level wall 30b is slid against the side surface of the other tooth portion 41b, and the outer wall of the inner layer high-level wall 29a and the inner peripheral surface of the outer layer high-level wall 30b are slid against each other to insert the outer layer high-level wall 30b. In other words, the outer layer high-level wall 30b is positioned between the inner layer high-level wall 29a and the inner wall of the slot 42. This configuration makes it easy to position the insulator 20b relative to the stator core 8.

Next, the outer wall of the outer layer low-level wall 28b is slid against the side of one of the teeth 41a and further inserted, and the base 21b is abutted against one end of the stator core 8. At this time, the outer wall of the inner layer high-level wall 29b is inserted along the inner wall of the outer layer high-level wall 30a, so that the outer layer high-level wall 30a is positioned between the inner layer high-level wall 29b and the inner wall of the slot 42. By this procedure, the insulator 20b can be placed on the other end of the stator core 8.

Furthermore, for the wall portion 22, the inner high-level wall 29 may be thinner than the outer low-level wall 28, and the outer high-level wall 30 may be thinner than the inner low-level wall 27. With this configuration, the outer high-level wall 30 can be easily inserted between the inner high-level wall 29 and the inner wall of the slot 42, improving assembly.

Next, the state of wall portion 22a and wall portion 22b overlapping on the inside of slot 42 will be described with reference to FIG. 5C.

In the inner layer portion 23, the positive inclined surface 25a faces the positive inclined surface 25b. In addition, the protruding tip of the inner layer low wall 27a faces the protruding tip of the inner layer high wall 29b, and the protruding tip of the inner layer low wall 27b faces the protruding tip of the inner layer high wall 29b.

In the outer layer portion 24, the inverse inclined surface 26a faces the inverse inclined surface 26b. In addition, the protruding tip of the outer layer low wall 28a faces the protruding tip of the outer layer high wall 30b, and the protruding tip of the outer layer low wall 28b faces the protruding tip of the outer layer high wall 30a.

Here, the inner layer portion 23 is connected by an inner layer low-level wall 27 having a lowest part and an inner layer high-level wall 29 having a highest part, with an inner layer inclined wall 31, with the height continuously changing, to form a positive inclined surface 25. Similarly, the outer layer portion 24 is connected by an outer layer high-level wall 30 having a highest part and an outer layer low-level wall 28 having a lowest part, with the height continuously changing, to form an anti-inclined surface 26, with an outer layer inclined wall 32.

The effect of using a slope instead of a step when changing the height will be described with reference to Figures 6A and B. Figures 6A and B are diagrams showing the movement when wall portion 22a and wall portion 22b are overlapped with the positions of insulator 20a arranged on the lower side and insulator 20b arranged on the upper side shifted in the circumferential direction. In Figures 6A and B, insulator 20a is shown shifted to the right relative to insulator 20b.

Here, Fig. 6A shows a structure in which the inner layer low wall 27 and the inner layer high wall 29 are directly connected, and the outer layer low wall 28 and the outer layer high wall 30 are directly connected. In other words, this structure has a step because the inner layer inclined wall 31 and the outer layer inclined wall 32 are not provided. Also, Fig. 6B shows a structure in which the height changes continuously by providing the inner layer inclined wall 31 and the outer layer inclined wall 32, so no step is created, i.e., it is a slope.

When attempting to overlap wall portion 22a and wall portion 22b in the structure of FIG. 6A, the tip of inner layer high wall 29a and the tip of inner layer high wall 29b come into contact with each other because insulator 20a is shifted to the right relative to insulator 20b. In other words, if insulator 20a and insulator 20b are shifted even slightly in the circumferential direction, it becomes difficult to overlap wall portion 22a and wall portion 22b.

In contrast, with the structure of FIG. 6B, even if insulator 20a is misaligned to the right relative to insulator 20b, positive inclined surface 25a and positive inclined surface 25b face each other and slide along the inclined surfaces, absorbing the misalignment. With this structure, when overlapping wall portion 22a and wall portion 22b, dimensional tolerances can be tolerated not only in the axial direction but also in the circumferential direction of slot 42. Since wall portion 22a and wall portion 22b can be overlapped without strict precision when assembling stator 2, productivity is improved.

Also, conventionally, the first wall portion 103 and the second wall portion 203 are overlapped by making the insulator B201 have a different shape from the insulator A101, as shown in Figures 7A and B.

According to the shape of this embodiment, while insulators 20a and 20b have the same shape, wall portions 22a and 22b are overlapped inside slot 42 to ensure insulation. Because insulators 20a and 20b have the same shape, only one type of mold is required, reducing costs and labor required to switch molds and increasing productivity.

The wall 22 has a cross-shaped structure in which the height of the inner layer 23 and the height of the outer layer 24 are switched at the wall midline 33. Furthermore, the inner high wall 29 has the same height as the outer high wall 30, and the inner low wall 27 has the same height as the outer low wall 28. In other words, the height of the inner layer 23 and the height of the outer layer 24 are linearly symmetrical with the wall midline as the axis of symmetry. With this configuration, the overlapping area of the inner layer 23 and the outer layer 24 is maximized, and the gap 46 is minimized when a pair of wall sections 22 are overlapped as shown in FIG. 5C, improving insulation.

In this embodiment, the wall portion 22 is described as having an inner layer portion 23 and an outer layer portion 24. The inner layer portion 23 and the outer layer portion 24 may be provided separately, or may be molded together to provide a single wall portion 22. It is sufficient that the insulators 20a and 20b have the same shape and the wall portions 22a and 22b can be overlapped inside the slots 42.

In addition, in this embodiment, the stator used in an outer rotor type motor has been described, but the present invention is not limited to this and can also be applied to an inner rotor type motor. In the outer rotor type, the tooth portion 41 protrudes radially outward from the outer peripheral surface of the cylindrical portion 43, but in the inner rotor type, it protrudes radially inward from the inner peripheral surface of the cylindrical portion 43. Accordingly, the protrusion portion 34 has a shape that protrudes radially inward from the outer layer inclined wall 32. In other words, it protrudes from the outer layer inclined wall 32 toward the outer peripheral side beyond the wall portion 22. In the inner rotor type, the tip of the protrusion portion 34 abuts the inner peripheral surface of the cylindrical portion 43, ensuring a physical distance between the wall portion 22 and the cylindrical portion 43.

The stator disclosed herein and the motor using it can be used as a motor for ceiling fans, etc.

REFERENCE SIGNS LIST 1 motor 2 stator 3 rotor yoke 4 rotor cover 5 shaft 6, 6a, 6b bearing 7 magnet 8 stator core 9 substrate 10 terminal 11 coil 20, 20a, 20b insulator 21, 21a, 21b base 22, 22a, 22b wall 23 inner layer 24 outer layer 25, 25a, 25b positive inclined surface 26, 26a, 26b reverse inclined surface 27, 27a, 27b inner layer lower wall 28, 28a, 28b outer layer lower wall 29, 29a, 29b inner layer high wall 30, 30a, 30b outer layer high wall 31 inner layer inclined wall 32 outer layer inclined wall 33 wall midline 34 protrusion 35 Winding opening 36 Winding locking portion 40 Center hole 41 Tooth portion 41a One tooth portion 41b Other tooth portion 42 Slot 43 Cylindrical portion 44a One winding portion 44b Other winding portion 45a One curved portion 45b Other curved portion 46 Gap 101 Insulator A
102 Base portion 103 First wall portion 201 Insulator B
202 Base 203 Second wall 204 First protrusion

Claims

a stator core having a plurality of teeth protruding radially outward from an outer circumferential surface of the cylindrical core and a slot formed between adjacent teeth;
a pair of insulators sandwiching the plurality of teeth from both sides in the axial direction of the cylindrical shape,
The insulator comprises:
a base portion configured with a surface perpendicular to the axial direction and abutting against an end portion of the stator core in the axial direction;
a wall portion extending in the axial direction from the base portion along an inner wall of the slot,
The wall portion is
an inner layer portion having a positive inclination surface whose height from the base portion increases at a predetermined angle from one side of the adjacent tooth portions forming the inner wall of the slot to the other side;
an outer layer portion located between the outer periphery of the inner layer portion and the inner wall of the slot, the outer layer portion having a reverse inclined surface whose height from the base decreases at the specified angle from the one side to the other side.
A stator core having a plurality of teeth protruding radially inward from an inner peripheral surface of the cylindrical core and slots formed between adjacent teeth;
a pair of insulators sandwiching the plurality of teeth from both sides in the axial direction of the cylindrical shape,
The insulator comprises:
a base portion configured with a surface perpendicular to the axial direction and abutting against an end portion of the stator core in the axial direction;
a wall portion extending in the axial direction from the base portion along an inner wall of the slot,
The wall portion is
an inner layer portion having a positive inclination surface whose height from the base portion increases at a predetermined angle from one side of the adjacent tooth portions forming the inner wall of the slot to the other side;
an outer layer portion located between the outer periphery of the inner layer portion and the inner wall of the slot, the outer layer portion having a reverse inclined surface whose height from the base decreases at the specified angle from the one side to the other side.
The inner layer portion is
The stator according to claim 1 , wherein the wall portion is integral with the outer layer portion.
The positive inclined surface in the inner layer portion is
The outer layer portion has a highest portion having a highest height from the base portion, a lowest portion having a lowest height from the base portion, and a middle portion having a height from the base portion intermediate between the highest portion and the lowest portion, and the inclined surface of the outer layer portion is
The inner layer portion has a highest portion, a lowest portion, and a middle portion at an outer periphery thereof,
The wall portion is
an inner layer lower wall including the lowest portion on the one side of the inner layer portion and constituting the wall portion on the one side at a height of the lowest portion;
an inner layer high wall that includes the highest portion on the other side of the inner layer portion and configures the wall portion on the other side at a height of the highest portion;
an inner layer inclined wall having the positive inclined surface and adjacent to the inner layer lower wall and the inner layer high wall;
an outer layer high wall including the highest part on the one side of the outer layer part and constituting the wall part on the one side at a height of the highest part;
an outer layer lower wall that includes the lowest portion on the other side of the outer layer portion and configures the wall portion on the other side at a height of the lowest portion;
3. The stator according to claim 1, further comprising: an outer layer inclined wall having the reverse inclined surface and adjacent to the outer layer lower wall and the outer layer high wall.
The thickness of the inner layer high wall is
The thickness of the inner layer lower wall is thinner than the thickness of the inner layer lower wall.
The thickness of the outer layer high wall is
The stator according to claim 4 , wherein the thickness is thinner than the thickness of the outer lower wall.
The pair of insulators include
With the base portion in contact with both ends of the stator core,
the positive inclined surface of the inner layer portion of one insulator faces the positive inclined surface of the inner layer portion of the other insulator,
5. The stator according to claim 4, wherein the counter-inclined surface of the outer layer portion of one insulator faces the counter-inclined surface of the outer layer portion of the other insulator.
a wall midline that is parallel to the axial direction and divides the wall into two equal parts, the one side and the other side;
The wall portion is
3. The stator according to claim 1, wherein a height of the inner layer portion from the base and a height of the outer layer portion from the base are symmetrical with respect to the wall midline.
The positive inclined surface in the inner layer portion is
The outer layer portion has a highest portion having a highest height from the base portion, a lowest portion having a lowest height from the base portion, and a middle portion having a height from the base portion intermediate between the highest portion and the lowest portion, and the inclined surface of the outer layer portion is
The inner layer portion has a highest portion, a lowest portion, and a middle portion at an outer periphery thereof,
The wall midline is
The stator of claim 7 including a median portion of said positive inclined surface and a median portion of said reverse inclined surface.
The outer layer portion is
The stator according to claim 7 , further comprising a protrusion on the wall midline, the protrusion protruding further toward an outer periphery than the wall.
The pair of insulators include
3. The stator according to claim 1, wherein one insulator and the other insulator have the same shape.
A motor equipped with a stator according to claim 1 or 2.