JP2003348782A - Stator, manufacturing method thereof and motor - Google Patents

Abstract

(57) Abstract: An object of the present invention is to provide a method of manufacturing a stator that can suppress an increase in the number of components and improve work efficiency while ensuring insulation of a coil. is there. The present invention provides a stator core having projection-shaped teeth, and a pair of outer circumferences extending radially outward from teeth protruding ends of the stator core and bendable in a tangential direction of the stator core. Insulator 3 having insulator piece 45 for use
0, 40).
In the method of manufacturing the stator 10 according to the present invention, after arranging the insulators 30 and 40 on the stator core 20, the coil 50 is wound around the teeth 21 of the stator core 20, and the pair of outer circumferential insulator pieces 45 are connected to the stator core 20 in the tangential direction. And bent in mutually opposite directions.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a stator, a stator manufacturing method, and a motor, and more particularly, to a stator having an insulator, a stator manufacturing method, and a motor.

[0002]

2. Description of the Related Art FIGS. 9 and 10 are explanatory views showing a process of manufacturing a stator conventionally used in a brushless motor. The stator 110 shown in FIG.
A plurality of stator cores 21 radially formed;
An insulator 140 is provided so as to cover the surface of the stator core 120. The coil 150 is provided with a nozzle 170 provided in the coil winding device.
Teeth 121 via insulator 140
It is wound around.

[0003] Thus, the coil 150 and the teeth 12
The insulation between the coil 150 and the teeth 121 is ensured by the interposition of the insulator 140 between the coil 140 and the coil 140, and a portion of the insulator 140 radially outward from the portion where the coil 150 is wound, Stator 110
By forming the outer insulator portion 145 along the tangential direction, the insulation between the coil 150 and an outer core (not shown) disposed radially outside the stator 110 is ensured.

On the other hand, a stator 210 according to another conventional example shown in FIG. 10 includes a stator core 220 having a plurality of projecting teeth 221 formed radially. A coil 250 is attached to the teeth 221. It is assembled in a state wound around the coil bobbin 270.

[0005] As described above, the coil 250 is assembled to the teeth 221 via the coil bobbins 270, so that the insulation between the coils 250 and the teeth 221 is ensured. Also on the radially outer part, the stator 210
Is formed along the tangential direction of, the insulation between the coil 250 and an outer core (not shown) disposed radially outside the stator 210 is secured.

[0006]

However, in the stator 110 shown in FIG.
Are formed so as to extend on both sides of the stator 110 in the tangential direction, so that when the coil 150 is wound around the teeth 121 using the nozzle 170, the outer insulator 1
There is a risk that the nozzle 170 will interfere with the nozzle 45.

Here, in order to prevent the nozzle 170 from interfering with the outer peripheral insulator portion 145, it is conceivable to provide a sufficient spacing between the adjacent teeth 121. There was a problem that it was not possible to reduce the size of the device.

If the outer insulator 145 is formed so as to extend to both sides of the stator 110 in the tangential direction, the distance c between the center axis L1 of the teeth 121 and the center axis L2 of the nozzle 170 is increased, so that the coil In the case of 150, there is a problem that a slack 151 occurs in a portion to be wound around the teeth 121, and it is difficult to align the coils 150 with the teeth 121 and wind them.

On the other hand, in the stator 210 shown in FIG. 10, in order to insulate the coil 250 from the surrounding members such as the stator core 220, it is necessary to use the same number of coil bobbins 270 as the teeth 121. As a result, there is a problem that the efficiency of the assembling operation is reduced, and the cost performance of the stator 210 cannot be improved.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-described problems, and has a stator and a stator capable of suppressing an increase in the number of parts and improving work efficiency while ensuring insulation of a coil. It is to provide a manufacturing method.

Another object of the present invention is to provide a stator capable of assembling coils in a high-density state in which coils are aligned neatly with teeth, and a method of manufacturing the stator.

It is another object of the present invention to provide a motor which can reliably insulate a coil from a member such as an outer core disposed radially outside a stator.

[0013]

According to a first aspect of the present invention, there is provided a stator having a plurality of radially-projecting teeth formed in a stator, a coil assembled to the teeth, and a coil. And an insulator for insulating the teeth from the outer periphery of the stator core. The outer insulator extends radially outward from the teeth protruding end of the stator core and can be bent in a tangential direction of the stator core. A stator having a piece formed thereon, wherein the insulator piece is bent in a tangential direction of the stator core after the coil is assembled to the teeth.

As described above, after the coil is assembled to the teeth, the outer peripheral insulator piece formed on the insulator is bent in the tangential direction of the stator core, so that the number of parts is not increased, and the outer circumferential insulator piece is radially outward of the stator. It is possible to reliably insulate the coil, such as the disposed outer core, from the member.

Further, before being bent in the coil assembling step, the outer circumferential insulator piece extends radially outward from the teeth protruding end portion of the stator core so as not to protrude in the tangential direction of the stator core. Therefore, the coil can be wound around the teeth with the nozzle close to the teeth.

Thus, the workability of assembling the coil to the stator can be improved, and the coil can be prevented from becoming loose between the teeth and the nozzle during the work of assembling the coil. The coils can be assembled in a high-density state in which the coils are neatly aligned with the teeth.

Also, by forming the outer circumferential insulator piece radially outward from the teeth protruding end of the stator core, the coil is previously formed into a convoluted shape that can be wound around the teeth. Since the coil can be assembled to the teeth in this shape, the working efficiency can be improved without being restricted by the working space such as the interval between the teeth.

In addition, since the coil can be formed into a convoluted shape before the coil is wound around the teeth, the coil can be preliminarily formed into a convoluted shape in which the coils are neatly arranged. Thereby, the coils can be assembled in a high-density state in which the coils are neatly aligned with the teeth.

At this time, like the stator according to the second aspect, the length of the outer circumferential insulator piece in the axial direction of the stator core is formed to be substantially the same as the length of the stator core in the axial direction. This is preferable because a member such as an outer core disposed radially outside the stator can be reliably insulated from the coil.

Further, as in the stator according to the third aspect,
The outer peripheral insulator pieces are provided at least at two locations at positions where the teeth protruding end portions of the insulator are located, and are formed radially outward of the stator when formed so as to be bendable in mutually opposite directions. This is preferable because it is possible to reliably insulate the coil such as the provided outer core from the member.

According to a fourth aspect of the present invention, there is provided a stator manufacturing method comprising: a stator core having projecting teeth; a stator core extending radially outward from a tooth protruding end of the stator core; An insulator having an outer peripheral insulator piece that can be bent in a tangential direction of the stator core, and a stator manufacturing method comprising: disposing the insulator on the stator core;
By winding a coil around the teeth of the stator core on which the insulator is disposed, by bending an outer circumferential insulator piece located at a protruding end side portion of the tooth around which the coil is wound, in a tangential direction of the stator core, Will be resolved.

As described above, after the coil is wound around the teeth, the outer circumferential insulator piece can be bent in the tangential direction of the stator core, so that the outer circumferential insulator piece is disposed radially outside the stator without increasing the number of parts. It is possible to reliably insulate the coil such as the outer core member from the coil.

Also, the outer insulator piece is extended radially outward from the teeth protruding end portion of the stator core without being bent, so that it does not protrude in the tangential direction of the stator core, thereby bringing the nozzle closer to the teeth. In this state, the coil can be wound around the teeth, so that the workability of assembling the coil to the stator can be improved.

Further, if the coil can be wound around the tooth in a state where the nozzle is close to the tooth, it is possible to prevent the coil from being loosened between the tooth and the nozzle. Therefore, the coils can be assembled in a high-density state where the coils are neatly arranged on the teeth.

According to a fifth aspect of the present invention, there is provided a stator having a stator core having protruding teeth, extending radially outward from a tooth protruding end of the stator core. An insulator having an outer peripheral insulator piece that can be bent in a tangential direction of the stator core, and a stator manufacturing method comprising: disposing the insulator on the stator core;
A coil formed in a convoluted shape that can be wound around the tooth is attached to the teeth of the stator core on which the insulator is provided, and an outer peripheral insulator piece located at a protruding end side portion of the tooth to which the coil is attached is attached. This is solved by being bent in the tangential direction of the stator core.

As described above, since the outer insulator piece can be bent in the tangential direction of the stator core after the coil is assembled to the teeth, the outer insulator piece is disposed radially outside the stator without increasing the number of parts. A member such as an outer core and the coil can be reliably insulated.

Also, by forming the outer circumferential insulator piece radially outward from the teeth protruding end of the stator core, the coil is previously formed into a convoluted shape that can be wound around the teeth. Since the coil can be assembled to the teeth with this shape, the working efficiency can be improved without being restricted by the working space such as the interval between the teeth.

Also, since the operation of forming the coil into a spiral shape can be performed before the coil is wound around the teeth, the coil can be shaped into a spiral shape in which the coils are arranged in advance in a neat manner. The coils can be assembled in a high-density state in which the coils are neatly aligned with the teeth.

According to a sixth aspect of the present invention, the above object is achieved by providing the stator according to any one of the first to third aspects.

As described above, when the stator according to any one of claims 1 to 3 is provided, the outer core disposed outside the stator in the radial direction by the outer circumferential insulator piece. This is preferable because the coil can be reliably insulated from the member.

[0031]

An embodiment of the present invention will be described below with reference to the drawings. The members, arrangements, and the like described below do not limit the present invention, and can be variously modified within the scope of the present invention.

1 to 8 show an embodiment of the present invention. FIG. 1 is a top view of a stator, FIG. 2 is a top view of a core, FIG. 3 is a top view of an upper insulator, and FIG. FIG. 5 is an exploded perspective view of a stator, FIG. 6 is an explanatory view showing a state where a coil is wound around a tooth, and FIG. 7 is an explanatory view showing a state where a coil is wound around a tooth. FIG. 8 is a sectional side view of a brushless motor to which the stator according to the present embodiment is applied.

A stator 10 according to an embodiment of the present invention shown in FIG. 1 is, for example, a three-phase stator used for a DC brushless motor, and includes a stator core 20 (inner core), an upper insulator 30, It has a lower insulator 40 and a coil 50.

The stator core 20 is a member disposed inside the outer core 60 and is formed by laminating iron thin plates in the axial direction. As shown in FIGS. Are formed in a shape in which the protruding teeth 21 are radially formed. Between adjacent teeth 21
A central hole 24 for inserting a rotor of a brushless motor, which will be described later, is formed in a central portion of a stator core main body portion 22 having a slot 21a formed therein and supporting a plurality of teeth 21.
Are formed so as to penetrate in the axial direction. The teeth 21 are formed such that the teeth protruding end portions 21b, which are portions on the free end side, abut on the inner peripheral surface of the outer core 60.

The upper insulator 30 shown in FIGS.
Is formed of an insulating member such as resin having a substantially similar shape to the above-mentioned stator core 20 and is slightly larger than the above-mentioned stator core 20, and the teeth insulating portion 3 for insulating the teeth 21 of the stator core 20 is provided.
1 and an upper insulator main body 32 for supporting a plurality of teeth insulating portions 31.

The upper insulator 30 is provided with a receiving recess 33 having substantially the same shape as the stator core 20 and having a depth approximately half the axial length of the stator core 20. By housing the stator core 20, the upper insulator 30 can cover a portion of the stator core 20 on one side in the axial direction.

Upper surface 32a of upper insulator main body 32
An annular terminal plate 35 is formed integrally with the center portion of the main body, and a central hole 34 for inserting a rotor of a brushless motor, which will be described later, passes through the upper insulator main body 32 and the terminal plate 35 in the axial direction. It is formed so that.

At predetermined positions on the outer peripheral surface of the terminal plate 35, terminal terminals 36 having the same number as the teeth 21 of the stator core 20 and having six poles are arranged. It is electrically connected by a terminal body (not shown) molded inside.

The lower insulator 40 shown in FIGS.
Similarly to the upper insulator 30, the stator core 20 is formed of an insulating member such as a resin having a substantially similar shape to the stator core 20 and slightly larger than the above-described stator core 20, and includes a teeth insulating portion 41 for insulating the teeth 21 of the stator core 20, and a plurality of teeth. Lower insulator main body 4 for supporting insulating portion 41
2 is provided.

The lower insulator 40 is provided with a receiving recess 43 having substantially the same shape as the stator core 20 and having a depth approximately half the axial length of the stator core 20. Is accommodated, the lower insulator 40 can cover the portion of the stator core 20 opposite to the side where the upper insulator 30 is disposed.

A central hole 44 penetrating in the axial direction is formed in a central portion of the lower insulator main body 42 so that a rotor of a brushless motor described later can be inserted therethrough.

A pair of thin outer peripheral insulator pieces 45 are formed at the projecting end of the tooth insulating portion 41 so as to extend radially outward from the tooth projecting end 21 b of the stator core 20. The length a of the insulator 45 for use in the axial direction of the stator core 20 is substantially the same as the length b of the stator core 20 in the axial direction.

For example, an elongated groove-shaped fold 45a is formed in advance at a connection portion between the outer peripheral insulator piece 45 and the teeth insulating portion 41, so that the outer peripheral insulator piece 45 is formed as shown by a dotted line in the drawing. It is configured to be able to be bent in the tangential direction of the stator core 20 and in directions opposite to each other.

When the upper insulator 30 and the lower insulator 40 are assembled to the stator core 20, the teeth 21 of the stator core 20 are surrounded by the teeth insulator 31 of the upper insulator 30 and the teeth insulator 41 of the lower insulator 40. As shown in FIG. 1, a coil 50 is attached to a portion of the tooth 21 surrounded by the teeth insulating portions 31 and 41 by a coil attaching method described later.

The outer insulator piece 45 is bent in the tangential direction of the stator core 20 to ensure insulation between the coil 50 and the outer core 60 disposed radially outside the stator 10. Between the teeth 21 and the coil 50, the teeth insulating portions 31,
The insulation between the coil 50 and the stator core 20 is ensured by interposing the 41.

To manufacture the stator 10 having the above configuration, first, the upper insulator 3 shown in FIG.
The lower and lower insulators 40 are assembled to the stator core 20 so as to be sandwiched from both axial sides of the stator core 20. At this time, the upper half of the stator core 20 in the axial direction is housed in the housing recess 33 of the upper insulator 30, and the lower half of the stator core 20 in the axial direction is housed in the housing recess 43 of the lower insulator 40.

As described above, the stator 10 according to this embodiment is
Thus, the stator core 20 can be easily and reliably insulated simply by using the two members of the upper insulator 30 and the lower insulator 40.

Next, the upper insulator 3
The coil 50 is mounted on the stator 10 with the 0 and lower insulators 40 mounted on the stator core 20.

In order to assemble the coil 50 with the stator 10, as shown in FIG. 6, the tip 50a of the coil 50 is connected to the terminal terminal 36 by a predetermined method or the like, and then provided in the coil winding device. The nozzle 70 is turned around the teeth 21 a predetermined number of times.

By doing so, the coil 50
Is, via a teeth insulating portion 31 of the upper insulator 30 and a tooth insulating portion 41 of the lower insulator 40,
The coil 50 is wound around the teeth 21, whereby the coil 50 is assembled with the stator 10 in an insulated state.

As described above, in the stator 10 of the present embodiment, the outer peripheral insulator piece 45 is not bent,
By extending the stator core 20 radially outward from the teeth protruding end portion 21b so as not to protrude in the tangential direction of the stator core 20, the coil 50 is attached to the teeth 21 in a state where the nozzle 70 is close to the teeth 21.
Can be wound, so that the coil 5
It is possible to improve the workability of assembling.

When the coil 50 can be wound around the teeth 21 in a state where the nozzle 70 is close to the teeth 21, the coil 50 is loosened between the teeth 21 and the nozzle 70. Since it is possible to prevent the coil 50 from being damaged, the coil 50 can be wound in a high-density state in which the coil 50 is neatly arranged on the teeth 21.

Then, a pair of outer circumferential insulator pieces 45 located on the protruding end side of the teeth 21 where the winding of the coil 50 has been completed are moved in the tangential direction of the stator core 20 and with each other as shown by the dotted line in the drawing. Fold in opposite directions.

By doing so, as shown in FIG. 1, the outer peripheral insulator piece 45 is attached to the stator core 20 at the teeth protruding end 21b of the stator core 20.
Are configured to extend on both tangential sides of the
Outer core 6 arranged radially outside stator 10
0 and the coil 50 are kept insulative.

As described above, the stator 10 according to this embodiment is
Then, after winding the coil 50 around the teeth 21, simply bending the outer circumferential insulator piece 45 in the tangential direction of the stator core 20 allows the outer core 60 and the coil 50 disposed radially outside the stator 10 to be securely connected to each other. Work efficiency can be improved.

The outer peripheral insulator piece 45 is bent so that the outer peripheral insulator piece 45 is bent to both sides of the stator core 20 in the tangential direction.
It is desirable to shape by applying heat, or to shape by pressing a tool or the like whose square shape is formed in advance.

Then, the above-described operation of assembling the coil 50 to the teeth 21 is performed for the other teeth 21 in the same manner, whereby the manufacturing process is completed, and the stator 10 shown in FIG. 1 is formed.

In the method of manufacturing the stator according to the present embodiment, a coil winding device is used for assembling the coil 50 to the stator 10, but in addition, the coil 50 may be previously formed into a spiral shape. It is also possible to assemble such that the convoluted coil 50 is attached to the teeth 21. Hereinafter, another embodiment in assembling the coil 50 to the stator 10 will be described.

FIG. 7 is an explanatory view showing another embodiment in assembling the coil 50 to the stator 10. In FIG. 7, the coil 50 and the coil assembling jig 71 are shown in a sectional view for easy understanding.

In FIG. 7, the stator core 20, the upper insulator 30, and the lower insulator 40 are already assembled by the method described above. The coil 50 is wound around a cylindrical coil assembly jig 71 having a central hole 71a, and is thereby formed into a predetermined spiral shape.

Then, the outer insulator piece 45 is
Without bending, the teeth protruding end 2 of the stator core 20
In this state, the end surface 71b of the coil assembling jig 71 around which the coil 50 is wound substantially overlaps with the projecting end surface of the teeth insulating portion 31. Then, the coil assembling jig 71 is mounted on the stator 10 such that the outer insulator piece 45 is inserted into the center hole 71a.

As described above, the outer insulator piece 45 is used.
Is extended radially outward of the stator core 20 from the teeth protruding end 21b of the stator core 20, so that it can be used as a guide member for positioning the coil assembling jig 71. Jig 71
Can be used as a mounting support member for the stator 10.

Then, the coil assembling jig 7 is
1 is mounted on the stator 10, and only the coil 50 is
The coil 50 is wound around the teeth 21 via the teeth insulating portions 31 and 41 by sliding the stator core 20 toward the center in the radial direction of the stator core 20.

At this time, since the coil 50 is formed in a convoluted shape by the coil assembling jig 71, the coil 50 is wound around the teeth 21 without being deformed. Further, since the coil assembling jig 71 is mounted on the stator 10 so that the end face 71b of the coil assembling jig 71 substantially overlaps with the protruding end face of the teeth insulating portion 31, when the coil 50 is slid, The coil assembly work can be reliably performed without the coil 50 being hooked on the teeth 21 or the like and being deformed.

As described above, according to the manufacturing method of the present embodiment, the coil 50 can be easily attached to the stator 10, so that the working efficiency can be improved.

Further, since the operation of shaping the coil 50 into a spiral shape can be performed before the coil 50 is wound around the teeth, the coil 50 can be shaped into a spiral shape in which the coils 50 are aligned in advance. , So that the coil 5
0 can be assembled to the teeth 21 in a high-density state in which they are neatly arranged.

In particular, when the coil 50 is formed of a thick line or when the number of turns is small, the coil 50 can be easily formed into a convoluted shape or assembled to the teeth 21, which is effective. .

It is preferable that the coil winding portion formed by the outer peripheral surface of the coil assembling jig 71 be subjected to a surface treatment such as applying a resin paint so that the coil 50 can slide smoothly. .

Then, one end of the coil 50 wound around the teeth 21 is connected to the terminal terminal 36 by a predetermined method such as winding. Although not shown, the other end of the coil 50 not connected to the terminal 36 is connected to a coil wound around another tooth in the same phase as the illustrated tooth 21. .

Then, the above-described operation of assembling the coil 50 to the teeth 21 is performed for the other teeth 21 in the same manner, whereby the manufacturing process is completed, and the stator 10 shown in FIG. 1 is formed.

Next, an example in which the stator 10 manufactured as described above is applied to a brushless motor will be described.

A brushless motor 80 shown in FIG. 8 is one in which the stator 10 according to the present embodiment is applied, and the stator 10 is disposed inside a housing 81. Inside the stator 10, a rotor 84 in which a magnet 83 is provided around a rotating shaft 82 is accommodated.
2 are bearings 85a provided at both ends of the housing 81,
By being pivotally supported by 85b, it is configured to rotate integrally.

At a predetermined position of the housing 81, a sensor unit 86 for detecting the rotational position of the rotor 84 is provided. By the sensor unit 86, a position detecting magnet 87 provided on the rotor 84 is provided. Is detected, and a rotation position detection signal based on the detection is output to an external drive control device (not shown).

A predetermined drive voltage is applied to the coil 50 of the stator 10 from an external drive control device, thereby generating a magnetic field in the stator 10. It is supposed to. Also,
The drive voltage to the stator 10 is controlled by an external drive control device according to the rotational position detection signal output from the sensor unit 86.

As described above, in the brushless motor 80 according to the present embodiment, since the coil 50 shown in FIG. 1 is provided with the stator 10 securely insulated by the outer insulator piece 45, the coil 50 is It can be reliably driven to rotate without contacting the rotating shaft.

As described above, according to the present embodiment, the following effects can be obtained. (A) In the stator 10 of the present invention shown in FIG. 1, the lower insulator 40 extends radially outward from the teeth protruding end 21 b of the stator core 20 and can be bent in the tangential direction of the stator core 20. After the coil 50 is wound around the teeth 21, the outer insulator piece 4 is formed.
By bending the stator core 5 in the tangential direction of the stator core 20, the outer core 60 disposed outside the stator 10 in the radial direction and the coil 50 can be reliably insulated without increasing the number of components.

(B) As shown in FIG. 6, before the outer circumferential insulator piece 45 is bent in the coil assembling step, the outer circumferential insulator piece 45 extends radially outward from the teeth protruding end portion 21b of the stator core 20. , So that it does not project in the tangential direction of the stator core 20,
Thus, during the coil assembling work, the coil 50 is attached to the teeth 21 with the nozzle 70 close to the teeth 21.
Can be wound.

Further, since it is possible to prevent the coil 50 from being loosened between the teeth 21 and the nozzle 70, it is possible to assemble the coils 50 in a high-density state where the coils 50 are aligned neatly with the teeth 21.

(C) As shown in FIG. 7, the outer circumferential insulator piece 45 extends radially outward from the teeth protruding end portion 21b of the stator core 20, so that the coil 50 is formed in advance. Since the coil 50 can be formed into a convoluted shape that can be wound around the teeth 21 and the coil 50 can be assembled to the teeth 21 in this shape, it is not restricted by the work space such as the interval between the teeth 21. Work efficiency can be improved.

Further, since the operation of shaping the coil 50 into a spiral shape can be performed before the coil 50 is wound around the teeth 21, it is necessary to form the coil 50 in a spiral shape in which the coils 50 are aligned in advance. Accordingly, during the coil assembling operation, the coil 50 can be assembled in a high-density state in which the coils 50 are aligned neatly with the teeth 21.

(D) Also, as shown in FIG. 5, the insulation of the stator core can be simply and reliably insulated simply by using two members, the upper insulator 30 and the lower insulator 40 on which the outer peripheral insulator piece 45 is formed. Since it can be performed, work efficiency can be improved.

(E) The outer insulator piece 45
Is a tooth protruding end 2 of the lower insulator 40.
1b are provided at least at two locations, and a pair of outer circumferential insulator pieces 45 are formed so as to be bent in mutually opposite directions, and the length a of the outer circumferential insulator pieces 45 in the axial direction of the stator core 20 is a Is formed to be substantially the same as the axial length b of the stator core, so that the outer core 60 and the coil 50 disposed radially outside the stator 10 can be reliably insulated.

(F) According to the brushless motor shown in FIG. 8, since the stator 10 is provided, the outer core 60 disposed radially outside the stator 10 by the outer circumferential insulator piece 45 is provided. (See FIG. 1), the coil can be reliably insulated.

The embodiment of the present invention can be modified as follows. (A) In the stator 10 according to the present embodiment, as shown in FIG. 5, two insulators, an upper insulator and a lower insulator, are used to insulate the stator core 20 and the coil 50. The described invention is not limited to this. That is, the outer circumferential insulator piece 45 is connected to the teeth projecting end 21 of the stator core 20.
If it is formed at a predetermined position so as to extend radially outward from b, members corresponding to the upper insulator 30 and the lower insulator 40 are formed by integrally molding the stator core 20 by injection molding or the like. And may be configured in a shape that can be divided in the radial direction of the stator core 20.

(B) The stator 10 according to the present embodiment
In the above, the outer insulator piece 45 is formed on the lower insulator 40, but the invention described in claim 2 is not limited to this. That is, the outer insulator piece 45 may be formed only on the upper insulator 30 as long as it is formed at a predetermined position so as to extend radially outward from the teeth protruding end 21b of the stator core 20. Further, it may be formed on both the upper insulator 30 and the lower insulator 40.

(C) The stator 10 according to the present embodiment
Although the terminal plate 35 provided on the upper insulator 30 has the same number of terminal terminals 36 as the number of the teeth 21 of the stator core 20, the present invention is not limited to this. May be configured to include a four-pole terminal terminal in which a neutral terminal is added to terminals of each of the U, V, and W phases.

(D) The stator 10 according to the present embodiment
Is composed of a three-phase stator, and the teeth 21 are 6
Although the poles are formed, the present invention is not limited to this, and the teeth 21 may be formed in nine poles.
The stator is not limited to three phases, but can be modified to four phases or the like.

The technical ideas other than the claims that can be grasped from the above embodiments are described below. (1) The insulator is formed to have an upper insulator covering one axial portion of the stator core and a lower insulator covering the other axial portion of the stator core. 2. The stator according to claim 1, wherein the piece is formed on at least one of the upper insulator and the lower insulator.

As described above, the insulator is formed having the upper insulator covering one axial portion of the stator core and the lower insulator covering the other axial portion of the stator core. When the piece is formed on at least one of the upper insulator and the lower insulator, the insulation of the stator core can be easily and reliably performed with a small number of members.
Work efficiency can be improved, which is preferable.

(2) The stator according to claim 1, wherein the insulator is assembled to the stator core by integral molding.

This is preferable because the stator core can be reliably insulated and the assembling process can be simplified.

[0092]

As described above in detail, according to the stator of the present invention, the outer periphery of the insulator extends radially outward from the teeth projecting end of the stator core and can be bent in the tangential direction of the stator core. After the coil is assembled to the teeth, the outer insulator piece is bent in the tangential direction of the stator core, so that the outer insulator piece is disposed radially outside the stator without increasing the number of parts. It is possible to reliably insulate the coil such as the outer core member from the coil.

Before being bent in the coil assembling step, the outer circumferential insulator piece extends radially outward from the teeth projecting end of the stator core so as not to project in the tangential direction of the stator core. Therefore, the coil can be wound around the teeth with the nozzle close to the teeth.

Thus, the workability of assembling the coil to the stator can be improved, and the coil can be prevented from becoming loose between the teeth and the nozzle during the work of assembling the coil. The coils can be assembled in a high-density state in which the coils are neatly aligned with the teeth.

According to the stator manufacturing method of the present invention, after the coil is wound around the teeth, the outer circumferential insulator piece can be bent in the tangential direction of the stator core, so that the number of parts is not increased. It is possible to reliably insulate the coil from a member such as an outer core disposed radially outside the stator.

Also, the nozzle is brought closer to the teeth by extending the outer circumferential insulator piece radially outward from the teeth protruding end of the stator core without bending it so as not to protrude in the tangential direction of the stator core. In this state, the coil can be wound around the teeth, so that the workability of assembling the coil to the stator can be improved.

Further, if the coil can be wound around the tooth in a state where the nozzle is close to the tooth, it is possible to prevent the coil from being loosened between the tooth and the nozzle. Therefore, the coils can be assembled in a high-density state where the coils are neatly arranged on the teeth.

Further, according to another stator manufacturing method of the present invention, the outer circumferential insulator piece is extended radially outward from the teeth protruding end of the stator core, so that the coil is previously formed. Can be assembled in a convoluted shape that can be wound around the teeth, and the coil can be assembled to the teeth in this shape, so that the work efficiency is improved without being restricted by the work space such as the interval between the teeth. Can be.

Also, since the operation of forming the coil into a spiral shape can be performed before the coil is wound around the teeth, it is possible to shape the coil into a spiral shape in which the coils are arranged in advance in a neat manner. The coils can be assembled in a high-density state in which the coils are neatly aligned with the teeth.

Further, according to the motor of the present invention, since the above-mentioned stator is provided, the outer peripheral insulator piece allows
The coil can be reliably insulated from a member such as an outer core disposed radially outside the stator.

[Brief description of the drawings]

FIG. 1 is a top view of a stator according to an embodiment of the present invention.

FIG. 2 is a top view of a stator core according to one embodiment of the present invention.

FIG. 3 is a top view of the upper insulator according to one embodiment of the present invention.

FIG. 4 is a top view of the lower insulator according to one embodiment of the present invention.

FIG. 5 is an exploded perspective view of a stator according to one embodiment of the present invention.

FIG. 6 is an explanatory diagram showing a state where a coil is wound around teeth of a stator core according to an embodiment of the present invention.

FIG. 7 is an explanatory diagram showing a state where a coil is wound around teeth of a stator core according to an embodiment of the present invention.

FIG. 8 is a sectional side view of a brushless motor to which the stator according to one embodiment of the present invention is applied.

FIG. 9 is an explanatory view showing a manufacturing process of a conventional stator.

FIG. 10 is an explanatory view showing a process of manufacturing a stator according to another example of the related art.

[Explanation of symbols]

10, 110, 210 Stator, 20, 120, 220
Stator core, 21, 121, 221 teeth, 2
1a slot, 21b teeth protruding end, 22 stator core main body, 24, 34, 44 central hole, 30
Upper insulator, 31, 41 Teeth insulating part, 32
Upper insulator body, 32a Upper surface, 33, 43
Housing recess, 35 terminal plate, 36 terminal terminal, 40 lower insulator, 42 lower insulator body, 45 outer insulator piece, 45a
Crease, 50, 150, 250 coil, 50a tip, 60 outer core, 70, 170 nozzle, 7
1 Coil assembly jig, 71a central hole, 71b end face, 8
0 brushless motor, 81 housing, 82 rotating shaft, 83 magnet, 84 rotor, 85a, 85b bearing, 86 sensor unit, 87 position detecting magnet, 140
Insulator, 145, 245 Outer insulator part, 270 Coil bobbin

   ────────────────────────────────────────────────── ─── Continuation of front page    F term (reference) 5H604 AA08 BB01 BB10 BB14 CC05                       CC16 DB01 PB03 QB03                 5H615 AA01 BB01 BB07 BB14 PP01                       PP12 PP15 QQ02 QQ19 RR01                       SS04 TT26

Claims (6)

[Claims] 1. A stator core in which a plurality of projecting teeth are radially formed, a coil attached to the teeth, and an insulator for insulating the coils from the teeth, the insulator comprising: A stator that extends radially outward from the teeth protruding end of the stator core and is formed with an outer peripheral insulator piece that can be bent in a tangential direction of the stator core, wherein the insulator piece is provided on the teeth. A stator, wherein the stator is bent in a tangential direction of the stator core after assembling the coil. 2. The stator according to claim 1, wherein the length of the outer circumferential insulator piece in the axial direction of the stator core is substantially equal to the length of the stator core in the axial direction. 3. The insulator piece for an outer periphery is provided at at least two places at positions where the teeth protruding ends of the insulator are located, and is formed so as to be bendable in directions opposite to each other. The stator according to claim 1. 4. A stator core having protruding teeth, and an insulator having an outer peripheral insulator piece extending radially outward from a teeth protruding end of the stator core and bendable in a tangential direction of the stator core. A method of manufacturing a stator, comprising: arranging the insulator on the stator core, winding a coil around a tooth of the stator core on which the insulator is arranged, and protruding end portions of the tooth around which the coil is wound. A stator manufacturing method characterized by bending an outer circumferential insulator piece located in a direction tangential to the stator core. 5. A stator core having protruding teeth, and an insulator having an outer peripheral insulator piece extending radially outward from a teeth protruding end of the stator core and bendable in a tangential direction of the stator core. A method for manufacturing a stator, comprising: arranging the insulator on the stator core, and assembling a coil formed into a convoluted shape that can be wound around the tooth, on a tooth of the stator core on which the insulator is arranged. A method of manufacturing a stator, comprising bending an outer circumferential insulator piece located at a protruding end side portion of a tooth to which the coil is attached in a tangential direction of the stator core. 6. A motor comprising the stator according to claim 1. 6. A motor comprising the stator according to claim 1. Description: