阅读说明：本技术 电枢以及电枢的制造方法 (Armature and method for manufacturing armature ) 是由 古贺清隆 小渊隆洋 加藤崇史 于 2019-10-09 设计创作，主要内容包括：本发明涉及一种电枢以及电枢的制造方法。在该电枢中,在在接合部处相互接合的第一扇形导体与第二扇形导体之间,在第一脚部的前端部与第二脚部主体部的轴向间设置有第一间隙部,并且在第二脚部的前端部与第一脚部主体部的轴向间设置有第二间隙部。(The present invention relates to an armature and a method of manufacturing the armature. In the armature, between the first sector conductor and the second sector conductor joined to each other at the joint portion, a first gap portion is provided between the tip portion of the first leg portion and the second leg portion main body portion in the axial direction, and a second gap portion is provided between the tip portion of the second leg portion and the first leg portion main body portion in the axial direction.)

1. An armature, characterized in that it comprises a first armature body,

the disclosed device is provided with:

an armature core provided with a plurality of slots extending in an axial direction;

a plurality of first sector conductors including first leg portions arranged on one side of the armature core in the axial direction and extending to the other side in the axial direction;

a plurality of second sector conductors including second legs disposed on the other axial side of the armature core and extending to one axial side; and

a coil portion including a joining portion provided on a front end portion side of the first leg portion of each of the plurality of first sector conductors and joined to a first surface provided to extend in the axial direction and a front end portion side of the second leg portion of each of the plurality of second sector conductors and joined to a second surface provided to extend in the axial direction in one of the slots or outside of the one of the slots in the axial direction,

the first leg portion has a first leg portion main body portion that is provided continuously from a first surface arrangement portion where the first surface is provided and on an opposite side of the distal end portion of the first leg portion, and that has a larger thickness in a joining direction that is a direction in which the first surface and the second surface are joined than the first surface arrangement portion,

the second leg portion has a second leg portion main body portion that is provided continuously from a second surface arrangement portion on which the second surface is provided and on an opposite side to the distal end portion of the second leg portion, and that has a larger thickness in the joining direction than the second surface arrangement portion,

between the first sector conductor and the second sector conductor joined to each other at the joint portion, a first gap portion is provided between the tip portion of the first leg portion and the axial direction of the second leg portion main body portion, and a second gap portion is provided between the tip portion of the second leg portion and the axial direction of the first leg portion main body portion.

2. The armature of claim 1,

each of the first and second faces being joined to a portion of each other at the joint,

the axial length of each of the first face and the second face is greater than the axial length of the engagement portion.

3. The armature of claim 1 or 2,

each of the first surface and the second surface extends in parallel with respect to the axial direction and is disposed so as to be opposed to each other in a radial direction,

the first face and the second face are radially joined to each other.

4. An armature according to any of claims 1 to 3,

at least one of a length in the axial direction of the first gap portion and a length in the axial direction of the second gap portion is larger than a thickness of the first surface arrangement portion and a thickness of the second surface arrangement portion in the engagement direction.

5. The armature of claim 4,

both the length of the first gap portion in the axial direction and the length of the second gap portion in the axial direction are larger than the thickness of the first surface arrangement portion and the thickness of the second surface arrangement portion in the engagement direction.

6. The armature of any of claims 1 to 5,

each of the first gap portion and the second gap portion is disposed within the slot.

7. The armature of any of claims 1 to 6,

each of the first gap portion and the second gap portion is provided at a position closer to at least one of one end surface and the other end surface of the armature core in the axial direction than a center of the armature core in the axial direction.

8. The armature of claim 7,

each of the first and second sector conductors has a U-shape including a pair of the first legs and a pair of the second legs,

the lengths in the axial direction of the pair of first leg portions and the pair of second leg portions are different from each other,

the first surfaces of the pair of first leg portions are joined to the second surfaces of the pair of second leg portions, whereby each of the first gap portion and the second gap portion is provided in the vicinity of one of the one side end surface and the other side end surface.

9. The armature of any of claims 1 to 8,

the joint portion further includes a conductive adhesive for bonding the first surface and the second surface and for electrically connecting the first leg portion and the second leg portion,

the conductive adhesive is applied to at least a part of a portion of the first surface facing the second gap portion and at least a part of a portion of the second surface facing the first gap portion, as viewed in the joining direction, in addition to a portion of at least one of the first surface and the second surface corresponding to the joint portion.

10. The armature of any of claims 1 to 9,

in one of the insertion grooves, a plurality of portions of the first leg portion provided with the first face and a plurality of portions of the second leg portion provided with the second face are alternately arranged in a radial direction,

each of the first and second gap portions is provided for each group of the first and second leg portions that are engaged with each other.

11. The armature of claim 10,

further comprises a sheet-like joint insulating member for insulating radially adjacent joint portions from each other,

the joint insulating member is provided so as to extend in the axial direction so as to cover both the first gap portion and the second gap portion when viewed in the radial direction.

12. The armature of any of claims 1 to 11,

the first surface disposition portion is provided continuously with the first leg main body portion via a first stepped portion including a corner inner surface facing the second gap portion and having a circular shape,

the second surface arrangement portion is provided continuously with the second leg main body portion via a second stepped portion including a corner inner surface facing the first gap portion and having a circular shape.

13. The armature of any of claims 1 to 12,

each of the front end portion of the first foot portion and the front end portion of the second foot portion has a tip-tapered shape.

14. A method for manufacturing an armature, comprising: an armature core provided with a plurality of slots extending in an axial direction; a plurality of first sector conductors including a first leg extending in the axial direction; and a plurality of second sector conductors including second legs extending in the axial direction, the method for manufacturing an armature including:

disposing each of the plurality of first sector conductors and each of the plurality of second sector conductors on one side in the axial direction of the armature core and on the other side in the axial direction of the armature core, in such a manner that a first surface provided to extend in the axial direction and a second surface provided to extend in the axial direction are opposed to each other within one of the slots or outside one of the slots in the axial direction, the first surface being provided to a front end side of the first leg portion of each of the plurality of first sector conductors and the second surface being provided to extend in the axial direction: and

a step of joining the first surface of the first leg portion and the second surface of the second leg portion which are disposed to face each other,

the first leg portion has a first leg portion main body portion that is provided continuously from a first surface arrangement portion where the first surface is provided and on an opposite side of the distal end portion of the first leg portion, and that has a larger thickness in a joining direction that is a direction in which the first surface and the second surface are joined than the first surface arrangement portion,

the second leg portion has a second leg portion main body portion that is provided continuously from a second surface arrangement portion on which the second surface is provided and on an opposite side to the distal end portion of the second leg portion, and that has a larger thickness in the joining direction than the second surface arrangement portion,

in the step of disposing the first sector conductor and the second sector conductor, the first sector conductor and the second sector conductor are disposed such that a first gap portion is provided between the tip portion of the first leg portion and the axial direction of the second leg portion main body portion, and a second gap portion is provided between the tip portion of the second leg portion and the axial direction of the first leg portion main body portion.

Technical Field

The present invention relates to an armature and a method of manufacturing the armature.

Background

Conventionally, an armature including an armature core provided with a plurality of slots extending in a central axis direction and a method of manufacturing the armature are known. For example, japanese patent application laid-open No. 2015-23771 discloses an armature and a method for manufacturing the armature.

The above-mentioned japanese patent application laid-open No. 2015-23771 discloses a rotating electric machine stator including a plurality of slots. The rotating electric machine stator includes a coil portion including a first conductor segment and a second conductor segment inserted into each of the plurality of slots and disposed to face each other in a central axis direction. Specifically, the first and second sector conductors are inserted into the slots from one side and the other side, respectively, in the direction of the central axis. In each of the plurality of slots, the facing surfaces of the first conductor segment and the second conductor segment, which are provided at the distal ends of the legs, are joined to each other by a conductive paste-like bonding material.

In the above-mentioned japanese patent application laid-open No. 2015-23771, the joining of the facing surfaces to each other using the bonding material is performed by heating the bonding material while pressing the first sector conductor and the second sector conductor against each other while pressurizing them in the central axis direction. In this way, the previously applied paste-like bonding material is melted by heat, and each of the first sector conductor and the second sector conductor is pressed in a state where the bonding material is melted, thereby bonding the first sector conductor and the second sector conductor. Further, the final bonding material is cured, whereby the opposed faces of the leg portions of each of the first sector conductor and the second sector conductor are joined to each other.

Patent document 1: japanese laid-open patent publication No. 2015-23771

However, although not clearly described in the above-mentioned japanese patent application laid-open No. 2015-23771, in the above-mentioned rotary electric machine stator, there is a case where the first sector conductors and the second sector conductors are inserted into the slots together in a state where the plurality of first sector conductors are aligned with each other and the height of the coil end portions is aligned with each other, and the plurality of second sector conductors are aligned with each other and the height of the coil end portions. Here, there is a case where a dimensional deviation due to a design error occurs between the plurality of first sector conductors and the plurality of second sector conductors. In this case, when the coil terminal portions are inserted in a state in which the heights of the coil terminal portions are aligned with each other, the leg portion having a relatively large length may abut against the leg portion to be joined due to dimensional variation, but the leg portion having a relatively small length may not abut against the leg portion to be joined. Specifically, after the legs joined to each other have the largest total length, the insertion of the sector conductor is prevented, and therefore, the legs of the other groups do not abut against each other. In this case, there is a problem that it is difficult to secure a joint area between the leg portions of the first sector conductor and the second sector conductor.

Disclosure of Invention

The present invention has been made to solve the above-described problems, and an object of the present invention is to provide an armature and a method of manufacturing the armature, in which even when the size of a sector conductor varies, the amount of projection of a coil end portion is uniform, and a joint area between leg portions is ensured.

In order to achieve the above object, an armature according to a first aspect of the present invention includes: an armature core provided with a plurality of slots extending in an axial direction; a plurality of first sector conductors including first leg portions arranged on one axial side of the armature core and extending to the other axial side; a plurality of second sector conductors including second legs disposed on the other axial side of the armature core and extending to the one axial side; and a coil section including a joint section provided on a tip end portion side of a first leg portion of each of the plurality of first sector conductors, and a first surface provided so as to extend in the axial direction and a tip end portion side of a second leg portion of each of the plurality of second sector conductors, and a second surface provided so as to extend in the axial direction and joined to the tip end portion side of the second leg portion of each of the plurality of second sector conductors in one slot or outside of the slot in the axial direction, the first leg portion having a first leg portion main body portion which is provided on an opposite side to the tip end portion of the first leg portion in a continuous manner from a first surface arrangement portion provided with the first surface and whose thickness in a joining direction, which is a direction in which the first surface and the second surface are joined, is larger than that of the first surface arrangement portion, the second leg portion having a second leg portion which is provided on an opposite side to the tip end portion of the second leg portion in a continuous manner from a second surface arrangement portion provided with the second surface, the second leg body portion has a larger thickness in the joining direction than the second surface arrangement portion, and a first gap portion is provided between the tip portion of the first leg and the second leg body portion in the axial direction and a second gap portion is provided between the tip portion of the second leg and the first leg body portion in the axial direction between the first sector conductor and the second sector conductor joined to each other at the joining portion. The term "joined" is used in a broad sense to include not only a state where the joining is performed via a bonding material (joining material), but also a state where the joining is performed only so as not to contact the bonding material (joining material).

In the armature according to the first aspect of the present invention, as described above, the first gap portion is provided between the tip portion of the first leg portion and the second leg portion main body portion in the axial direction, and the second gap portion is provided between the tip portion of the second leg portion and the first leg portion main body portion in the axial direction. Thus, even when there is a variation in the dimensions of the first and second sector conductors during manufacture, the variation can be absorbed by the first and second gap portions. As a result, the tip end portions of the conductors, which are relatively large in size, of the plurality of first sector conductors and the plurality of second sector conductors are brought into contact with the conductors to be joined, so that the axial movement of the other first sector conductors and the other second sector conductors can be prevented from being stopped. As a result, even in a state where the coil end portions of the first and second fan-shaped conductors are aligned in height, the conductor of the first and second fan-shaped conductors, which is manufactured to have a relatively small size, can be easily brought into contact with the conductor to be joined at the joint portion. Thus, even when the sizes of the first sector conductor and the second sector conductor are deviated, the protruding amounts of the coil end portions of the first sector conductor and the second sector conductor are made uniform, and the joint area of the first leg portion and the second leg portion is ensured.

A method for manufacturing an armature according to a second aspect of the present invention is a method for manufacturing an armature including: an armature core provided with a plurality of slots extending in an axial direction; a plurality of first sector conductors including a first leg extending in an axial direction; and a plurality of second sector conductors including second legs extending in the axial direction, the method for manufacturing an armature including: disposing each of the plurality of first sector-shaped conductors and each of the plurality of second sector-shaped conductors on one side in an axial direction of the armature core and on the other side in the axial direction of the armature core such that a first surface provided on a leading end portion side of a first leg portion of each of the plurality of first sector-shaped conductors and provided so as to extend in the axial direction and a second surface provided on a leading end portion side of a second leg portion of each of the plurality of second sector-shaped conductors and provided so as to extend in the axial direction are opposed to each other within one slot or to an outer side in the axial direction of one slot; and a step of joining a first surface of a first leg and a second surface of a second leg which are arranged to face each other, the first leg having a first leg main body portion which is provided continuously from a first surface arrangement portion provided with the first surface and is provided on the opposite side of the tip portion of the first leg, and a thickness in a joining direction which is a direction in which the first surface and the second surface are joined is larger than that of the first surface arrangement portion, the second leg having a second leg main body portion which is provided continuously from a second surface arrangement portion provided with the second surface and is provided on the opposite side of the tip portion of the second leg, and a thickness in the joining direction is larger than that of the second surface arrangement portion, in the step of arranging the first sector conductor and the second sector conductor, in such a manner that a first gap portion is provided between the tip portion of the first leg and the axial direction of the second leg main body portion, and a second gap portion is provided between the tip portion of the second leg and the axial direction of the first leg main body portion, a first sector conductor and a second sector conductor are arranged.

In the armature manufacturing method according to the second aspect of the present invention, as described above, the first sector conductor and the second sector conductor are arranged so that the first gap portion is provided between the tip portion of the first leg portion and the second leg portion in the axial direction of the second leg portion main body portion, and the second gap portion is provided between the tip portion of the second leg portion and the first leg portion main body portion in the axial direction. Thus, even when there is a variation in the dimensions of the first and second sector conductors during manufacture, the variation can be absorbed by the first and second gap portions. As a result, the tip end portions of the conductors, which are relatively large in size, of the plurality of first sector conductors and the plurality of second sector conductors are brought into contact with the conductors to be joined, so that the axial movement of the other first sector conductors and the other second sector conductors can be prevented from being stopped. As a result, even in a state where the coil end portions of the first and second fan-shaped conductors are aligned in height, the conductor of the first and second fan-shaped conductors, which is manufactured to have a relatively small size, can be easily brought into contact with the conductor to be joined at the joint portion. Thus, even when the sizes of the first sector conductor and the second sector conductor are deviated, the amount of projection of the coil end portion of each of the first sector conductor and the second sector conductor can be made uniform, and the joint area of the first leg portion and the second leg portion can be secured.

According to the present invention, as described above, even when the fan-shaped conductors vary in size, the protruding amount of the coil end portion can be made uniform, and the joint area between the leg portions can be secured.

Drawings

Fig. 1 is a plan view showing the structure of a stator (rotating electric machine) according to the first and second embodiments.

Fig. 2 is a perspective view showing the structure of the stator according to the first embodiment.

Fig. 3 is a plan view showing the structure of the stator core of the first and second embodiments.

Fig. 4 is a sectional view showing the structure of the first insulating member and the second insulating member of the first embodiment.

Fig. 5 is a circuit diagram showing a wiring structure of the coil part of the first embodiment.

Fig. 6 is a cross-sectional view showing the structure of the sector conductor of the first embodiment.

Fig. 7 is a perspective view showing the structure of the first sector conductor according to the first embodiment. (FIG. 7A is a perspective view of the first sector conductor viewed from the radially inner side. FIG. 7B is a perspective view of the first sector conductor viewed from the radially inner side.)

Fig. 8 is a perspective view showing the structure of the second sector conductor according to the first embodiment. (FIG. 8A is a perspective view of the second sector conductor viewed from the radially inner side. FIG. 8B is a perspective view of the second sector conductor viewed from the radially inner side.)

Fig. 9 is a diagram showing the structure of the power segment conductor according to the first embodiment.

Fig. 10 is a diagram showing the structure of the outer diameter side neutral point conductor according to the first embodiment.

Fig. 11 is a diagram showing a structure of the inner diameter side neutral point conductor according to the first embodiment.

Fig. 12 is a sectional view taken along line 1000-1000 of fig. 1.

Fig. 13 is a partially enlarged view of the vicinity of the joint portion of fig. 12.

Fig. 14 is a partially enlarged view of the vicinity of the joint portion of fig. 13.

Fig. 15 is a sectional view schematically showing the structure of the first insulating member of the first embodiment.

Fig. 16 is a sectional view showing the structure of the first insulating member and the second insulating member including the anchor layer before foaming according to the first embodiment.

Fig. 17 is a sectional view showing the structure of the first insulating member and the second insulating member including the foamed anchor layer according to the first embodiment.

Fig. 18 is a sectional view showing the structure of the second insulating member according to the first embodiment.

Fig. 19 is a perspective view showing the structure of the second insulating member according to the first embodiment.

Fig. 20 is an exploded perspective view of the stator core, the first insulating member, and the second insulating member of the first embodiment.

Fig. 21 is a diagram showing the thickness of the first insulating member and the thickness of the second insulating member in the first embodiment.

Fig. 22 is a flowchart for explaining an insertion process of the conductor into the slot according to the first embodiment.

Fig. 23 is an exploded perspective view of the stator of the second embodiment.

Fig. 24 is a cross-sectional view showing the structure of a leg of the sector conductor according to the second embodiment.

Fig. 25 is a perspective view showing the structure of the first sector conductor according to the second embodiment. (FIG. 25A is a perspective view of the first sector conductor as viewed from the radially inner side. FIG. 25B is a perspective view of the first sector conductor as viewed from the radially inner side.)

Fig. 26 is a perspective view showing the structure of the second sector conductor according to the second embodiment. (FIG. 26A is a perspective view of the second sector conductor viewed from the radially inner side; FIG. 26B is a perspective view of the second sector conductor viewed from the radially inner side.)

Fig. 27 is a sectional view of the coil part and the stator core of the second embodiment.

Fig. 28 is a partially enlarged view of the vicinity of the contact portion of fig. 27.

Fig. 29 is a sectional view showing the structure of an insulating member according to the second embodiment.

Fig. 30 is a cross-sectional view showing the structure of the insulating layer and the fixed layer of the core leg portion insulating portion of the second embodiment.

Fig. 31 is a flowchart for explaining a method of manufacturing a stator according to the second embodiment.

Fig. 32 is a sectional view of the vicinity of the joint portion in the first modification of the first embodiment.

Fig. 33 is a sectional view of the vicinity of the joint portion in a second modification of the first embodiment.

Fig. 34 is a perspective view of a first sector conductor and a second sector conductor of a third modification of the first and second embodiments. (FIG. 34A is a perspective view of the first sector conductor viewed from the radially inner side, and FIG. 34B is a perspective view of the second sector conductor viewed from the radially outer side.)

Detailed Description

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

[ first embodiment ]

[ Structure of stator ]

The structure of the stator 100 according to the first embodiment will be described with reference to fig. 1 to 21. The stator 100 has a circular ring shape centered on the center axis C1. The stator 100 is an example of an "armature" according to the present invention.

In the present specification, as shown in fig. 1, the "axial direction (central axis direction, axial direction)" refers to a direction (Z direction) along the central axis C1 (rotation axis of the rotor 101) of the stator 100. The "circumferential direction" refers to the circumferential direction (a1 direction, a2 direction) of the stator 100. The "radial direction" refers to the radial direction (R direction) of the stator 100. Further, "radially inward" refers to a direction (R1 direction) toward the center axis C1 of the stator 100 in the radial direction. Further, "radially outward" refers to a direction (R2 direction) toward the outside of the stator 100 in the radial direction.

The stator 100 and the rotor 101 together form a part of a rotating electric machine 102. The rotating electrical machine 102 is configured as a motor, an engine, or a motor and an engine, for example. As shown in fig. 1, the stator 100 is disposed radially outside a rotor 101 provided with permanent magnets (not shown). That is, in the first embodiment, the stator 100 constitutes a part of the inner rotor type rotating electric machine 102. In addition, the radial direction is an example of the "joining direction" of the technical solution.

As shown in fig. 2, the stator 100 includes: a stator core 10, a first insulating member 20, and a coil section 30. The coil portion 30 includes a first coil assembly 30a (counter-guide side coil) and a second coil assembly 30b (guide side coil). The coil portion 30 is formed of a plurality of sector conductors 40 (see fig. 4). In the first embodiment, the stator 100 includes the second insulating member 21 provided separately from the first insulating member 20 (see fig. 4). The stator core 10 is an example of an "armature core" according to the present invention. The second insulating member 21 is an example of the "joint insulating member" according to the embodiment.

(construction of stator core)

The stator core 10 has a cylindrical shape with a central axis C1 (see fig. 1) as a central axis. The stator core 10 is formed by, for example, laminating a plurality of electromagnetic steel plates (e.g., silicon steel plates) in the axial direction. As shown in fig. 3, the stator core 10 is provided with: the back yoke 11 has an annular shape when viewed in the axial direction, and a plurality of slots 12 provided radially inside the back yoke 11 and extending in the axial direction. Further, a plurality of teeth 13 are provided on the stator core 10 on both sides in the circumferential direction of the slot 12.

The insertion groove 12 is a portion surrounded by the wall portion 11a of the back yoke 11 provided radially outward and the circumferential side surfaces 13a of the two teeth 13. The slot 12 is provided with an opening 12a that opens radially inward. The insertion grooves 12 are open to both axial sides. The teeth 13 are formed to protrude radially inward from the back yoke 11, and a protruding portion 13b constituting an opening 12a of the slot 12 is formed at a radially inner front end portion.

The opening portion 12a has an opening width W1 in the circumferential direction. Here, the opening width W1 corresponds to the distance between the tip portions of the convex portions 13b of the teeth 13. In addition, the width W2 of the portion of the slot 12 in which the coil portion 30 is disposed is larger than the opening width W1. That is, the socket 12 is configured as a half-open socket. Here, the width W2 corresponds to the distance between the circumferential side surfaces 13a of the teeth 13 disposed on both circumferential sides of the slot 12. In addition, the width W2 of the slot 12 is substantially constant throughout the radial direction.

(Structure of coil section)

As shown in fig. 4, the coil portion 30 is formed of a square wire. For example, the coil portion 30 is made of copper or aluminum.

As shown in fig. 2, the coil portion 30 is formed by axially combining and joining a first coil assembly 30a provided on one axial side (the side of the arrow Z2) and a second coil assembly 30b provided on the other axial side (the side of the arrow Z1). The first coil block 30a and the second coil block 30b are each formed in an annular shape centered on the same center axis C1 (see fig. 1) as the stator core 10. As shown in fig. 4, in the first embodiment, a coil portion 30 is formed by joining first leg portions 71 and second leg portions 81, which will be described later, of a plurality of segment conductors 40 at a joining portion 90.

The coil portion 30 is configured as a wave winding coil, for example. The coil portion 30 is formed as an 8-turn coil. That is, the coil unit 30 is configured such that 8 sector conductors 40 are arranged in parallel in the radial direction in the slot 12.

Structure of wiring of coil section

As shown in fig. 5, the coil unit 30 is configured to generate magnetic flux by supplying 3-phase ac power from a power supply unit (not shown). Specifically, the coil section 30 is connected (wired) by a 3-phase Y-wiring. That is, coil unit 30 includes U-phase coil unit 30U, V phase coil unit 30V and W-phase coil unit 30W. Also, a plurality of (e.g., two) neutral points N are provided at the coil portion 30. Specifically, the coil portions 30 are wired in 4 parallel (star-wired). That is, the U-phase coil portion 30U is provided with 4 neutral point connection end portions NtU and 4 power line connection end portions PtU. The V-phase coil portion 30V is provided with 4 neutral point connection end portions NtV and 4 power line connection end portions PtV. W-phase coil unit 30W is provided with 4 neutral point connection end portions NtW and 4 power line connection end portions PtW. In the following description, when the U phase, the V phase, and the W phase are not particularly distinguished with respect to the neutral point connection end portion and the power line connection end portion, only the neutral point connection end portion Nt and the power line connection end portion Pt are described.

Structure of coil assembly

As shown in fig. 2, the first coil assembly 30a is constituted by a plurality of first sector conductors 70 (hereinafter, referred to as "first conductors 70") as the sector conductors 40. It is preferable that only the plurality of first conductors 70 are combined to constitute the first coil component 30 a.

In addition, the second coil component 30b includes: a plurality of (e.g., 3) power sector conductors 50 (hereinafter, referred to as "power conductors 50") as the sector conductors 40, a plurality of (e.g., two) neutral point sector conductors 60 (hereinafter, referred to as "neutral point conductors 60") as the sector conductors 40, and a second sector conductor 80 (hereinafter, referred to as "second conductor 80") as a conductor different from the power conductor 50 and the neutral point conductor 60 among the plurality of sector conductors 40 and constituting the coil part 30. That is, the power conductor 50 and the neutral point conductor 60 provided in the stator 100 are all provided in the second coil assembly 30 b.

(construction of sector conductor)

As shown in fig. 6, the sector conductor 40 is configured as a square wire having a substantially rectangular shape in cross section. An insulating film 40a having a thickness t1 is provided on the conductor surface 40b of the sector conductor 40. The thickness t1 of the insulating film 40a is set to a degree that can ensure the interphase insulating performance (insulation between the first coil end portions 72, insulation between the second coil end portions 82, see fig. 2), for example. In fig. 6, the magnitude relation such as thickness is shown in a prominent manner for the sake of explanation, but the present invention is not limited to the example shown in the figure.

Structure of first conductor and second conductor

As shown in fig. 7 and 8, the plurality of segment conductors 40 includes a plurality of first conductors 70 arranged on one side (the Z2 direction side) in the axial direction of the stator core 10, and a plurality of second conductors 80 located on the other side (the Z1 direction side) in the axial direction of the stator core 10 and arranged to face the first conductors 70 in the axial direction. That is, the coil portion 30 is formed by joining the first conductor 70 and the second conductor 80 that are axially divided into two. Here, the second conductor 80 refers to the sector-shaped conductor 40 other than the power conductor 50 and the neutral point conductor 60 among the sector-shaped conductors 40 constituting the second coil assembly 30 b. In the first embodiment, the first conductor 70 includes the first leg portion 71 having the axial length L1 and extending in the axial direction. The first leg portion 71 extends to the other axial side (the Z1 direction side). The second conductor 80 includes a second leg 81 disposed on the Z1 direction side of the first leg 71, having a length L2 greater than the length L1 in the axial direction, and extending in the axial direction. The second leg 81 extends to one axial side (the Z2 direction side).

In the first embodiment, as shown in fig. 7A and 7B, the plurality of first conductors 70 are formed such that a pair of first leg portions 71 disposed in different slots 12 are connected to each other, respectively, and thereby have a U-shape (substantially U-shape) as viewed in the radial direction. The coil pitch of the first conductor 70 is 6. That is, the pair of first leg portions 71 are arranged at different positions in the circumferential direction with the size of 6 slots 12. That is, 5 slots 12 are provided between the slot 12 in which one of the pair of first legs 71 is disposed and the slot 12 in which the other first leg 71 is disposed. Specifically, the first conductor 70 includes a pair of first leg portions 71 and a first coil end portion 72, which are arranged in different slots 12 and are formed linearly along the axial direction. The first leg portion 71 is a portion that is disposed from an axial position of an end surface 10a (see fig. 2) of the stator core 10 in the axial direction into the slot 12, and the first coil end portion 72 is a portion that is formed continuously with the first leg portion 71 and is disposed at a position axially outward of the end surface 10a of the stator core 10. In addition, the first coil end portion 72 has a curved shape that is bent in the axial direction. The first coil end portion 72 has a first crank portion 73 formed in a crank shape that is formed by bending the width of 1 sector conductor 40 in the radial direction in a step shape when viewed in the axial direction. In other words, the width in the radial direction of the first crank part 73 is 2 times the width of the 1 fan-shaped conductor 40. The end surface 10a is an example of "one-side end surface" of the present invention.

The axial lengths L1 of the pair of first leg portions 71 are substantially equal to each other. The axial length L1 is a length of a portion of the first conductor 70 that linearly extends in the axial direction within the slot 12. The axial length L1 is smaller than the axial length L3 of the stator core 10 (see fig. 2). Further, the axial length L3 of the stator core 10 refers to the distance (interval) in the axial direction between the end face 10a and the end face 10b in the axial direction. The end surface 10b is an example of the "other end surface" of the invention.

Similarly, as shown in fig. 8A and 8B, the second conductor 80 includes a pair of second leg portions 81 disposed in the slot 12 and a second coil end portion 82. In addition, the second coil end portion 82 has a second crank portion 83. In the first embodiment, the second conductor 80 is formed in a U shape by connecting a pair of second legs 81 disposed in different slots 12 to each other. The axial lengths L2 of the pair of second legs 81 of the second conductor 80 are substantially equal to each other. In addition, the axial length L2 of the pair of second legs 81 of the second conductor 80 is greater than the axial length L1 of the pair of first legs 71 of the first conductor 70 (L2 > L1). The axial length L2 is the length of the portion of the second conductor 80 that extends linearly in the axial direction within the slot 12.

Structure of power conductor

As shown in fig. 9, in the power conductor 50, a plurality of (e.g., 4) power wire connection end portions Pt of the same phase are electrically connected to each other, and the connected plurality of power wire connection end portions Pt are electrically connected to one power terminal member 51. The power conductor 50 is joined to the power terminal member 51 by the second leg 81 joined to one of the pair of first legs 71 (see fig. 12). The power conductor 50 has a function of supplying electric power from a power supply unit (not shown) to the coil unit 30.

Specifically, the power conductor 50 includes: the power cable connector includes an outer diameter side power conductor 52 disposed radially outward of the slot 12 (see fig. 1) and having a power cable connecting end Pt, and an inner diameter side power conductor 53 disposed radially inward and axially outward of the outer diameter side power conductor 52 and having a power cable connecting end Pt. In other words, the power conductor 50 is formed in a bifurcated shape.

The outer diameter side power conductor 52 and the power terminal member 51 are electrically connected by a lead wire 54. The inner diameter side power conductor 53 and the power terminal member 51 are electrically connected by a lead wire 54. The outer diameter side power conductor 52 and the inner diameter side power conductor 53 are electrically connected via the power terminal member 51 and the lead wire 54. The lead wire 54 is formed of, for example, a twisted wire (conductor), and the insulating tube 51a is disposed on the outer periphery.

The second leg 81 is provided on each of the outer diameter side power conductor 52 and the inner diameter side power conductor 53, and the first coil end portion 72 or the second coil end portion 82 is not provided. In the outer diameter side power conductor 52 and the inner diameter side power conductor 53, the lead wire 54 and the second leg 81 are joined via the conductor plate 55. For example, the joining can be performed by brazing, or welding (for example, any of resistance welding, arc welding, laser welding, or high-energy beam welding).

Structure of neutral point conductor

As shown in fig. 1, the neutral point conductor 60 includes an outer diameter side neutral point conductor 61 and an inner diameter side neutral point conductor 62. As shown in fig. 5, outer diameter side neutral point conductor 61 and inner diameter side neutral point conductor 62 each include a neutral point N, and are electrically connected to neutral point connection end NtU of U-phase coil portion 30U, neutral point connection end NtV of V-phase coil portion 30V, and neutral point connection end NtW of W-phase coil portion 30W.

As shown in fig. 10, the outer diameter side neutral point conductor 61 includes two U-phase W-phase neutral point segment conductors 61a and two V-phase neutral point segment conductors 61 b. The U-phase W-phase neutral point segment conductor 61a includes a U-phase second leg 81 connected to the first leg 71 of the U-phase first conductor 70 in the 3-phase ac, a W-phase second leg 81 connected to the W-phase first leg 71, and two neutral point coil end portions 61c connecting the U-phase second leg 81 and the W-phase second leg 81. The neutral point coil end portion 61c is continuously formed with the second leg portion 81 for the U phase, and is continuously formed with the second leg portion 81 for the W phase.

The U-phase W-phase neutral point sector conductor 61a is formed in a substantially U-shape (substantially コ -shape) as viewed from the radially inner side. The V-phase neutral point sector conductor 61b is formed substantially linearly as viewed from the radially inner side.

As shown in fig. 1, the neutral point coil end portion 61c is formed in the circumferential direction radially outward of the second coil end portion 82 of the second conductor 80. Further, the neutral point coil end portion 61c is formed in a substantially arc shape as viewed in the direction of arrow Z2. One of the two U-phase W-phase neutral point segment conductors 61a is disposed axially outward (toward the arrow Z1) of the other.

As shown in fig. 10, the V-phase neutral point segment conductor 61b includes a V-phase second leg portion 81 connected to the V-phase first conductor 70, and a neutral point coil end portion 61 d. The neutral point coil terminal portion 61d is formed to protrude outward in the axial direction (in the direction of arrow Z1) from the second leg 81. The two neutral point coil terminal portions 61d are electrically joined to both of the two neutral point coil terminal portions 61c by being joined to each other.

As shown in fig. 11, the inner diameter side neutral point conductor 62 includes two U-phase W-phase neutral point segment conductors 62a and two V-phase neutral point segment conductors 62 b. The U-phase W-phase neutral point segment conductor 62a includes a U-phase second leg 81 connected to the first leg 71 of the U-phase first conductor 70 in the 3-phase ac, a W-phase second leg 81 connected to the W-phase first conductor 70, and a neutral point coil terminal portion 62c connecting the U-phase second leg 81 and the W-phase second leg 81. The neutral point coil end portion 62c is formed continuously with the second leg portion 81 for the U phase, and is formed continuously with the second leg portion 81 for the W phase. Thus, the U-phase W-phase neutral point segment conductor 62a is formed in a substantially U-shape as viewed from the radially inner side. The V-phase neutral point sector conductor 62b is formed substantially linearly as viewed from the radially inner side.

As shown in fig. 12, the neutral point coil end portion 62c is formed so as to protrude axially outward from the second coil end portion 82 of the second conductor 80. The neutral point coil end portion 62c is disposed in close proximity to the second coil end portion 82 of the second conductor 80 on the axially outer side, and is formed along the circumferential direction as viewed in the axial direction. One of the two U-phase W-phase neutral point segment conductors 62a is arranged radially outward of the other.

The V-phase neutral point segment conductor 62b includes a V-phase second leg 81 connected to the first leg 71 of the V-phase first conductor 70, and a neutral point coil end portion 62 d. The neutral point coil end portion 62d is formed to protrude outward in the axial direction (in the direction of arrow Z1) from the second leg 81. The two neutral point coil end portions 62d are electrically joined to both of the two neutral point coil end portions 62c by being joined to each other.

(Structure of Joint)

As shown in fig. 12 and 13, a plurality of first leg portions 71 are provided in one slot 12 so as to be adjacent to each other in the radial direction of the stator core 10. In addition, a plurality of second leg portions 81 are provided in one slot 12 so as to be adjacent to each other in the radial direction of the stator core 10. The joint portion 90 is formed by joining a first surface 71a, which will be described later, of the first leg portion 71 to a second surface 81a, which will be described later, of the second leg portion 81.

In addition, in one slot 12, the plurality of first conductors 70 (first legs 71) are joined to the plurality of second conductors 80 (second legs 81). Specifically, in one slot 12, a plurality of first surface arrangement portions 71b of the first leg portion 71, on which first surfaces 71a, which will be described later, are provided, and a plurality of second surface arrangement portions 81b of the second leg portion 81, on which second surfaces 81a, which will be described later, are provided, are alternately arranged in the radial direction. That is, the joining portions 90 of the plurality of first leg portions 71 and the plurality of second leg portions 81, which will be described later, are arranged adjacent to each other in the radial direction in one slot 12.

Specifically, the joint portions 90 are configured such that the joint portions 90 adjacent in the radial direction overlap each other when viewed in the radial direction. Specifically, the plurality of (all of) the joint portions 90 disposed in one slot 12 are configured to overlap when viewed in the radial direction. That is, all the joint portions 90 disposed in one slot 12 are disposed in parallel in the horizontal direction. In other words, the positions of the plurality of engaging portions 90 in the axial direction are substantially equal to each other in one slot 12. As described later, the joint portion 90 is a portion where the first surface 71a of the first leg portion 71 and the second surface 81a of the second leg portion 81 are joined (overlapped) when viewed in the radial direction.

In addition, as shown in fig. 14, each of the front end portion 71c of the first footer 71 and the front end portion 81c of the second footer 81 has a tapered shape. Specifically, the front end portion 71c of the first leg portion 71 and the front end portion 81c of the second leg portion 81 each have a tapered shape as viewed in the circumferential direction (a direction).

A first surface 71a extending in the axial direction is provided on the tip end portion 71c side of the first leg portion 71 of each of the plurality of first conductors 70. Further, a second surface 81a extending in the axial direction is provided on the distal end portion 81c side of the second leg 81 of each of the second conductors 80. Specifically, each of the first surface 71a and the second surface 81a is provided so as to extend in parallel with the axial direction. The first leg 71 and the second leg 81 include a first surface arrangement portion 71b provided with the first surface 71a and a second surface arrangement portion 81b provided with the second surface 81a, respectively.

The first leg portion 71 includes a first leg main body portion 71d provided continuously to the first surface arrangement portion 71b provided with the first surface 71 a. The first leg portion main body portion 71d is provided on the opposite side (the Z2 direction side) from the distal end portion 71c with respect to the first surface arrangement portion 71 b. The second leg 81 has a second leg body 81d provided continuously to a second surface arrangement portion 81b on which the second surface 81a is provided. The second leg body portion 81d is provided on the opposite side (the Z1 direction side) from the distal end portion 81c with respect to the second surface arrangement portion 81 b. Specifically, the first surface arrangement portion 71b is provided continuously with the first leg main body portion 71d via a first step portion 71g described later. The second surface arrangement portion 81b is provided continuously with the second leg main body portion 81d via a second stepped portion 81g described later.

The thickness t2 in the radial direction of the first surface arrangement portion 71b provided with the first surface 71a is smaller than the thickness t3 in the radial direction of the first leg main body portion 71 d. Specifically, the thickness t2 of the first surface arrangement portion 71b is about 1/2 of the thickness t3 of the first leg main body portion 71 d. In addition, the radial thickness t4 of the second surface arrangement portion 81b provided with the second surface 81a is smaller than the radial thickness t5 of the second leg body portion 81 d. Specifically, the thickness t4 of the second surface arrangement portion 81b is about 1/2 of the thickness t5 of the second leg main body portion 81 d. The thickness t2 is substantially equal to the thickness t4, and the thickness t3 is substantially equal to the thickness t 5.

The coil unit 30 (see fig. 2) includes a joining portion 90 where the first surface 71a and the second surface 81a are joined in one slot 12. That is, the joint portion 90 is located between the end surface 10a (see fig. 2) and the end surface 10b (see fig. 2) of the stator core 10 in the axial direction.

Here, in the first embodiment, as shown in fig. 14, the first surface 71a and the second surface 81a are joined to each other in the radial direction (R direction) at the joint portion 90. Specifically, a part of the first surface 71a on the side of the leading end 71c is joined to a part of the second surface 81a on the side of the leading end 81c via a face portion 71e in the radial direction. In other words, the first surface 71a and the second surface 81a are joined in a state of being shifted in the axial direction.

The first surface 71a (surface portion 71e) and the second surface 81a (surface portion 81e) extend in parallel with the axial direction and are disposed so as to face each other in the radial direction. That is, each of the first face 71a (face portion 71e) and the second face 81a (face portion 81e) extends orthogonally with respect to the radial direction. In addition, the first face 71a (face portion 71e) is directed radially inward (R1 direction side), and the second face 81a (face portion 81e) is directed radially outward.

In the first embodiment, the length L4 (see fig. 14) of the first surface 71a in the axial direction and the length L5 (see fig. 14) of the second surface 81a in the axial direction are longer than the length L6 (see fig. 14) of the engaging portion 90 in the axial direction. The length L4 of the first surface 71a is substantially equal to the length L5 of the second surface 81 a. Further, the length L6 of the joint 90 refers to the axial length of the face portion 71e and the face portion 81 e.

In the first embodiment, the first gap portion 74 is provided between the first conductor 70 and the second conductor 80 that are axially opposed to each other, and between the tip portion 71c of the first leg portion 71 and the second leg portion 81 in the axial direction. Further, a second gap portion 84 is provided between the first conductor 70 and the second conductor 80 that are axially opposed to each other, and between the tip portion 81c of the second leg portion 81 and the first leg portion 71 in the axial direction. Specifically, the first gap portion 74 is provided between the distal end portion 71c of the first leg portion 71 and the second leg main body portion 81d of the second leg portion 81 in the axial direction. Further, the second gap portion 84 is provided between the distal end portion 81c of the second leg portion 81 and the first leg main body portion 71d of the first leg portion 71 in the axial direction.

Further, the first gap portion 74 is surrounded by the first leg portion 71 and the second leg portion 81 joined to each other and the second insulating member 21 adjacent to each other on the radially inner side (the R1 direction side) as viewed in the circumferential direction (a direction). Further, the second gap portion 84 is surrounded by the first leg portion 71 and the second leg portion 81 joined to each other and the second insulating member 21 adjacent to each other on the radially outer side (the side of the direction R2) as viewed in the circumferential direction (the a direction). The configuration of the second insulating member 21 will be described in detail later.

In addition, each of the first gap portion 74 and the second gap portion 84 is provided for each set of the first leg portion 71 and the second leg portion 81 that are joined to each other. That is, a plurality of the first gap portions 74 and the second gap portions 84 are arranged in parallel in the radial direction (8 in the first embodiment, see fig. 13). Specifically, the plurality of first gap portions 74 overlap each other and the plurality of second gap portions 84 overlap each other as viewed in the radial direction.

The axial length L7 of the first gap portion 74 is substantially equal to the axial length L8 of the second gap portion 84. The length L7 of the first clearance portion 74 is the distance in the axial direction between the distal end portion 71c of the first leg portion 71 and the second leg portion 81. The length L8 of the second gap portion 84 is the distance in the axial direction between the distal end portion 81c of the second leg 81 and the first leg 71.

In the first embodiment, both the length L7 in the axial direction of the first gap portion 74 and the length L8 in the axial direction of the second gap portion 84 are larger than the thickness t2 of the first surface arrangement portion 71b provided with the first surface 71a of the first leg portion 71 and the thickness t4 of the second surface arrangement portion 81b provided with the second surface 81a of the second leg portion 81 in the radial direction. The length L7 of the first gap portion 74 and the length L8 of the second gap portion 84 are set to lengths that can absorb variations in dimensions that occur during the manufacture of the first conductor 70 and the second conductor 80, and variations in assembly that occur when the first conductor 70 and the second conductor 80 are assembled.

In addition, a first stepped portion 71g is provided between the first surface arrangement portion 71b of the first footer 71 where the first surface 71a is provided and the first footer main body portion 71d, the first stepped portion 71g including a corner inner surface 71f facing the second gap portion 84 and having a circular shape. In addition, a second stepped portion 81g is provided between the second surface arrangement portion 81b of the second leg portion 81, at which the second surface 81a is provided, and the second leg main body portion 81d, the second stepped portion 81g including a corner inner surface 81f facing the first gap portion 74 and having a circular shape. Specifically, the corner inner surface 71f and the corner inner surface 81f have circular arc shapes having a radius of curvature smaller than the radial thickness t2 of the first surface arrangement portion 71b and the radial thickness t4 of the second surface arrangement portion 81b, respectively. In this case, the first leg portion 71 and the second leg portion 81 are provided with a flat surface 71h and a flat surface 81h which are provided continuously with the corner inner surface 71f and the corner inner surface 81f, respectively. The flat surface 71h and the flat surface 81h are each provided to extend orthogonally to the axial direction.

As shown in fig. 13, each of the first gap portion 74 and the second gap portion 84 is disposed in the slot 12. Specifically, the first gap portion 74 and the second gap portion 84 are disposed entirely within the slot 12.

Further, since the length L1 (see fig. 7) of the pair of first legs 71 and the length L2 (see fig. 8) of the pair of second legs 81 are different from each other, the first surface 71a of the first leg 71 and the second surface 81a of the second leg 81 are joined to each other, and thereby each of the first gap portion 74 and the second gap portion 84 (the joint portion 90) is provided on the end surface 10a side with respect to the axial center C2 (see fig. 12) in the axial direction. Thus, each of the first gap portion 74 and the second gap portion 84 is provided in the vicinity of the end surface 10a of the stator core 10 with respect to the axial center C2 of the stator core 10. Specifically, the edge of the second gap portion 84 on one side in the axial direction (the Z2 direction side) is provided at substantially the same position in the axial direction as the end surface 10a of the stator core 10. Further, the edge portion on one side (the Z2 direction side) in the axial direction of the second gap portion 84 may be provided within a range shifted from the end surface 10a in the Z1 direction or the Z2 direction by a substantially insulation creepage distance. Further, the axial center C2 is an example of the "center" of the solution.

The stator 100 further includes a conductive adhesive 91 that bonds the first surface 71a to the second surface 81a and that electrically connects the first leg 71 to the second leg 81 at the joint 90. The conductive adhesive 91 is, for example, a paste-like bonding material (silver nanopaste) in which metal particles obtained by reducing silver to a nano level are contained as conductive particles in a solvent. The conductive adhesive 91 is melted by heat.

The conductive adhesive 91 contains a member (resin member) that volatilizes when heated, and has a function of bringing the first surface 71a and the second surface 81a into close proximity by reducing the volume of the conductive adhesive 91 by heating the volatilized member. In order to join the first surface 71a and the second surface 81a, the first conductor 70 and the second conductor 80 are assembled in a state in which the conductive adhesive 91 is applied to a portion (at least one of the surface portion 71e and the surface portion 81e) of at least one of the first surface 71a and the second surface 81a, which portion corresponds to the joint portion 90. In fig. 14, the thickness of the conductive adhesive 91 is shown as being protruded for the sake of explanation, but the present invention is not limited to the example shown in the figure.

Here, in the first embodiment, the conductive adhesive 91 is applied to the face portion 71i facing the second gap portion 84 in the first face 71a and the face portion 81i facing the first gap portion 74 in the second face 81a as viewed in the radial direction, in addition to at least one of the face portion 71e and the face portion 81 e. Specifically, the conductive adhesive 91 is applied to the entirety of each of the face portion 71i and the face portion 81 i. That is, the entire first surface 71a and the entire second surface 81a are covered with the conductive adhesive 91 when viewed in the radial direction. Further, the conductive adhesive 91 is not applied to each of the corner inner surfaces 71f and 81 f. Further, the face portion 71i and the face portion 81i are one example of "a portion facing the second gap portion" and "a portion facing the first gap portion" of the technical solutions, respectively.

(construction of first insulating Member)

As shown in fig. 4, the first insulating member 20 is disposed between the wall portion 11a and the teeth 13 and the first leg portion 71 and the second leg portion 81 (the sector conductor 40). As shown in fig. 15, the first insulating member 20 has a 3-layer configuration. Specifically, as shown in fig. 12, the first insulating member 20 includes: in the slot 12, a fixing layer 20c is provided between the wall portion 11a of the back yoke 11 and the circumferential side surface 13a (see fig. 4) of the tooth 13 and the first leg portion 71 and the second leg portion 81, and the insulating layer 20a insulating the wall portion 11a and the circumferential side surface 13a from the first leg portion 71 and the second leg portion 81 and overlapping a portion 20b of a position (region) (P2) of the insulating layer 20a different from the axial position P1 corresponding to the joint portion 90, and fixes the stator core 10 and the second leg portion 81. The anchor layer 20c is preferably configured as an adhesive layer including an adhesive. The position P2 includes, for example, the entire region in the slot 12 including the portion other than the axial position P1 in the axial direction and the portion near the end surface 10b of the stator core 10 (including the portion axially outward of the slot 12).

Further, the first insulating member 20 is disposed so as to integrally cover the peripheries of the plurality of second legs 81 arranged in parallel in the radial direction, as viewed in the direction of the arrow Z2. In other words, both circumferential sides and both radial sides of the plurality of second leg portions 81 arranged in parallel in the radial direction are covered with the first insulating member 20. Thereby, the insulation of the joint 90 from the stator core 10 can be ensured by the first insulating member 20.

The insulating layer 20a is made of, for example, polyphenylene Sulfide (PPS) Resin. The insulating layer 20a may be formed in a nonwoven fabric form such as aramid paper. As shown in fig. 12, the insulating layer 20a is provided so as to extend from one end surface 10a to the other end surface 10b of the stator core 10 in the axial direction. That is, the insulating layer 20a is disposed in each slot so as to cover the wall portion 11a and the circumferential side surface 13 a. Note that "covering" does not mean only covering the entire wall portion 11a and the circumferential side surface 13a, but means a broad concept including a case where a radially inner portion (tip clearance portion) of the circumferential side surface 13a is exposed as shown in fig. 4.

As shown in fig. 15, the fixing layer 20c contains a foaming agent 20d (expanding agent) that expands by heat. Specifically, the fixing layer 20c is formed by mixing a thermosetting resin 20e into a plurality of capsule bodies as the foaming agent 20d, for example. The foaming agent 20d is configured to expand the volume of the capsule body by being heated to the foaming temperature T1 or higher. The fixed layer 20c is heated in the manufacturing process of the stator 100, for example, and thereby increases from the thickness t6 (see fig. 16) to the thickness t7 (see fig. 17). Thus, when the fixing layer 20c is heated, the foaming agent 20d foams (expands), and thereby the space between the second leg portion 81 and the wall portion 11a and the circumferential side surface 13a is filled.

The thermosetting resin 20e is heated to a temperature higher than the foaming temperature T1, i.e., a curing temperature T2 or higher, and is cured. The thermosetting resin 20e constituting the anchor layer 20c is, for example, an epoxy resin. The fixing layer 20c is configured such that the thermosetting resin 20e is cured when heated, thereby bonding and fixing the second leg portion 81 to the wall portion 11a and the circumferential side surface 13 a.

As shown in fig. 12, at least a part of the second leg portion 81 and the wall portion 11a and the circumferential side surface 13a constituting the insertion groove 12 are filled with the fixing layer 20c containing the foaming agent 20d in a foamed state at a position P2 different from the axial position P1 corresponding to the joint portion 90. Specifically, the fixed layer 20c is provided to overlap with a portion 20b of the insulating layer 20a on the other axial side (the Z1 direction side) than the axial position P1 corresponding to the joint 90. In other words, the fixed layer 20c is provided to overlap with a portion 20b of the insulating layer 20a on the other axial side from the vicinity of the end face 10a on one axial side (the Z2 direction side). The fixing layer 20c is provided in the slot 12 so as to overlap with the portion 20b of the insulating layer 20a disposed between the second leg 81 and the stator core 10. For example, as shown in fig. 15, the fixing layer 20c is provided so as to overlap the insulating layer 20a so as to sandwich the insulating layer 20a at a portion 20b of the insulating layer 20a at a position different from the position in the axial direction corresponding to the joint portion 90.

In the first embodiment, as shown in fig. 13, a first insulating member 20 provided between the slot 12 and the coil portion 30 and a second insulating member 21 provided separately from the first insulating member 20 are provided. As shown in fig. 18, of the joint portions 90 obtained by joining the first surface 71a of the first leg portion 71 of the first conductor 70 and the second surface 81a of the second leg portion 81 of the second conductor 80 between the coils adjacent in the radial direction in one slot 12, the joint portions 90 adjacent in the radial direction are insulated from each other by the sheet-like second insulating member 21 provided separately from the first insulating member 20. The "coil" refers to a linear portion of the coil portion 30 that is disposed in the slot 12 after the first conductor 70 and the second conductor 80 are joined. Therefore, a plurality of coils are arranged in one slot 12. The second insulating member 21 is an example of the "joint insulating member" according to the embodiment.

Here, in the first embodiment, as shown in fig. 18, the second insulating member 21 is formed by folding 1 sheet of an insulating member such as a Nomex material, for example. Further, the second insulating member 21 includes: the facing surface insulating portion 21a covering the facing surface 90a of the joining portion 90 adjacent in the radial direction and the circumferential surface insulating portion 21b continuing from both circumferential ends of the facing surface insulating portion 21a and covering at least an insulating distance amount of any one of the circumferential surfaces 90b of the joining portion 90 adjacent in the radial direction. The facing surfaces 90a of the joining portions 90 indicate radially outer and radially inner surfaces of the joining portions 90 adjacent in the radial direction, which face each other. In addition, the insulation distance is a length along the radial direction of the circumferential surface insulation portion 21b, and refers to a sufficient distance (creeping distance) for insulating the joining portions 90 adjacent in the radial direction from each other.

As shown in fig. 19, the second insulating member 21 includes a portion 21c covering the radially outer side of the joint portion 90 disposed on the outermost diameter side and a portion 21d covering the radially inner side of the joint portion 90 disposed on the innermost diameter side.

In the second insulating member 21, the facing surface insulating portions 21a adjacent in the radial direction are connected to one or the other in the circumferential direction by the circumferential surface insulating portion 21 b. Specifically, the radially outer facing surface insulating portion 21a of the pair of facing surface insulating portions 21a arranged adjacent to each other in the radial direction is formed continuously with the circumferential surface insulating portion 21b provided on one side in the circumferential direction and the radially inner facing surface insulating portion 21a of the pair of facing surface insulating portions 21a with the circumferential surface insulating portion 21b provided on the other side in the circumferential direction. In other words, the circumferential surface 90b on the a1 direction side of the joint 90 and the circumferential surface 90b on the a2 direction side of the joint 90 are alternately covered with the circumferential surface insulating portion 21 b. In other words, the second insulating member 21 is configured to discontinuously cover the circumferential surfaces 90b of the plurality of joining portions 90 arranged adjacent to each other in the radial direction.

Thus, the second insulating member 21 has a meandering shape (corrugated shape) as viewed from the axial direction. Further, since the radially adjacent joint portions 90 disposed in one slot 12 are insulated from each other by one second insulating member 21, all the joint portions 90 in the slot 12 are insulated from each other. This can reduce the number of steps for disposing the second insulating member 21, compared to a case where the plurality of joining portions 90 disposed in one slot 12 are individually covered with an insulating member.

As shown in fig. 19, the second insulating member 21 is configured to be expandable and contractible in the radial direction. This is because the second insulating member 21 is formed of a flexible sheet-like insulating member, and is configured to discontinuously cover the circumferential surface 90b of the plurality of joining portions 90 arranged adjacent to each other in the radial direction. Thus, when the first leg portion 71 and the second leg portion 81 are joined, even if the first leg portion 71 and the second leg portion 81 are pressed in the radial direction or the axial direction, the second insulating member 21 can be deformed together with the movement of the first leg portion 71 and the second leg portion 81.

Here, in the first embodiment, as shown in fig. 13, the second insulating member 21 is provided so as to extend in the axial direction so as to cover both the first gap portion 74 and the second gap portion 84 when viewed in the radial direction. Specifically, the second insulating member 21 is disposed such that one axial edge (Z2 direction side) protrudes outward (Z2 direction side) from the axial end face 10a of the stator core 10. Further, the edge portion of the second insulating member 21 on the other side (Z1 direction side) in the axial direction is provided on the other side (Z1 direction side) in the axial direction than the edge portion of the first gap portion 74 on the other side (Z1 direction side) in the axial direction in the slot 12.

As shown in fig. 13, the first insulating member 20 is also disposed so as to protrude outward (toward the Z2 direction) from the end surface 10a of the stator core 10 in the axial direction, together with the second insulating member 21. The height h1 of the portion of the second insulating member 21 protruding outward from the end surface 10a of the stator core 10 is substantially equal to the height h2 of the portion of the first insulating member 20 protruding outward from the end surface 10a of the stator core 10. The amounts of projection of the first insulating member 20 and the second insulating member 21 from the end surface 10a of the stator core 10 are adjusted to such an extent that the first insulating member 20 and the second insulating member 21 are bent without contacting the first coil end portion 72 of the first segment conductor 70.

In addition, as shown in fig. 20, the length L12 of the second insulating member 21 is smaller than the length L11 of the first insulating member 20 in the axial direction. Specifically, the length L11 of the first insulating member 20 is greater than the length L3 in the axial direction of the stator core 10. In addition, the length L12 of the second insulating member 21 is smaller than the length L3 of the stator core 10. In addition, the second insulating member 21 is provided so as to cover the joint 90 and extend from the joint 90 to the Z1 direction side and the Z2 direction side. The length L12 of the second insulating member 21 is adjusted based on the magnitude of the voltage applied to the coil part 30 and the like (required creepage distance). In fig. 20, the first conductor 70 and the second conductor 80 are not illustrated for the sake of simplicity.

In addition, the length L12 of the second insulating member 21 is smaller than the length L11 of the first insulating member 20, and therefore, as shown in fig. 21, the first insulating member 20 includes a portion 20f overlapping with the second insulating member 21 as viewed in the radial direction, and a portion 20b not overlapping. Specifically, the first insulating member 20 and the second insulating member 21 overlap each other near the end (end surface 10a) in the axial direction in the slot 12. Also, the thickness t11 of the portion 20f of the first insulating member 20 overlapping the second insulating member 21 is smaller than the thickness t12 of the portion 20b of the first insulating member 20 not overlapping the second insulating member 21.

In addition, the thickness t13 of the second insulating member 21 is smaller than the thickness t 11. In addition, the thickness t12 is a thickness obtained by increasing the thickness t7 of the two anchor layers 20c by an amount (t7 × 2) from the thickness t 11.

The second insulating member 21 is arranged on one side (the Z2 direction side) in the axial direction with respect to the fixed layer 20c of the first insulating member 20, and is arranged between the joint portions 90 in the radial direction, thereby insulating the joint portions 90 from each other. Specifically, the fixed layer 20c is provided to overlap with a portion 20b of the insulating layer 20a that does not overlap with the second insulating member 21 as viewed in the radial direction. The insulating layer 20a is disposed in a portion 20f overlapping the second insulating member 21 when viewed in the radial direction.

(Process for inserting conductor)

Next, a process of inserting each of the sector conductors into the slot 12 will be described with reference to fig. 22.

As shown in fig. 22, in step S1, the plurality of second conductors 80 are inserted into the slot 12 from the Z1 direction side. At this time, the second coil end portions 82 are simultaneously pressed from above (the Z1 direction side) by the disk-shaped plate-like member, whereby the second conductors 80 are inserted into the slots 12. This makes the amount of projection of each second coil end portion 82 of the plurality of second conductors 80 from the stator core 10 uniform.

Next, in step S2, the second insulating member 21 is inserted into the slot 12. Specifically, the second insulating member 21 is disposed on the distal end side of the plurality of second conductors 80 inserted into the slot 12.

Then, in step S3, the plurality of first conductors 70 are inserted into the slot 12 from the Z2 direction side. At this time, the first coil end portions 72 are simultaneously pressed from the lower side (the Z2 direction side) by the disc-shaped plate-like member, thereby inserting the plurality of first conductors 70 into the slots 12. Thereby, the amount of projection of the plurality of first coil end portions 72 from the stator core 10 is made uniform.

[ second embodiment ]

Next, a stator 200 and a method of manufacturing the stator 200 according to a second embodiment will be described with reference to fig. 1, 3, and 23 to 31. Unlike the first embodiment, the stator 200 of the second embodiment is configured such that the first surface 171a is joined to the second surface 181a by the biasing force of the spring member 210. Note that the same components as those of the first embodiment are denoted by the same reference numerals as those of the first embodiment, and description thereof is omitted.

[ Structure of stator ]

The structure of the stator 200 according to the second embodiment will be described with reference to fig. 1, 3, and 23 to 30. The stator 200 is an example of an "armature" according to the present invention.

As shown in fig. 1, the stator 200 and the rotor 101 together form a part of a rotating electric machine 202. As shown in fig. 23, the stator 200 includes: a sheet-like insulating member 121, and a coil portion 130 (see fig. 1). Further, the coil portion 130 includes: a first coil block 130a (counter-leading-side coil) (see fig. 27) and a second coil block 130b (leading-side coil) (see fig. 27). The coil portion 130 is formed of a plurality of sector conductors 140 (see fig. 24). The insulating member 121 is an example of the "joint insulating member" according to the invention.

(construction of sector conductor)

As shown in fig. 24, a first leg 171 (second leg 181) to be described later in the sector conductor 140 is exposed on the conductor surface 140b so as not to be covered with an insulating film (see fig. 24). In fig. 24, only the first conductor 170 described later is shown, but the second conductor 180 is also the same and thus not shown.

Structure of first conductor and second conductor

As shown in fig. 25A, 25B, 26A, and 26B, the plurality of sector-shaped conductors 140 include a plurality of first conductors 170 arranged on one side (the Z2 direction side) in the axial direction of the stator core 10, and a plurality of second conductors 180 arranged on the other side (the Z1 direction side) in the axial direction of the stator core 10. In addition, the first conductor 170 includes a first leg 171 having an axial length L31, a first coil end portion 172, and a first crank portion 173. The second conductor 180 includes a second leg portion 181 having a length L32 in the axial direction, a second coil end portion 182, and a second crank portion 183. The length L31 of the first leg 171 is substantially equal to the length L32 of the second leg 181.

As shown in fig. 27, the stator 200 includes, in each of the plurality of slots 12, a spring member 210 interposed between the coil portion 130 and the opening 12a (convex portion 13b) of the slot 12. That is, the spring member 210 is provided in the distal end gap 12b provided radially inside the insertion groove 12.

The spring member 210 is configured to press the coil portion 130 from the radially inner side so that the first surface 171a of the first leg 171 of the first conductor 170 contacts the second surface 181a of the second leg 181 of the second conductor 180. The first surface 171a of the first leg 171 is in contact with the second surface 181a of the second leg 181, thereby forming the contact portion 190. The contact portion 190 is an example of the "engagement portion" of the invention.

The first face 171a and the second face 181a are pressed by the spring member 210 to thereby contact each other, and contact each other without a bonding material between the first face 171a and the second face 181 a. That is, the first surface 171a and the second surface 181a are not joined, and the contact state between the first surface 171a and the second surface 181a is maintained by the pressing force of the spring member 210.

Each of the plurality of contact portions 190 is disposed in the center portion of the stator core 10 in the axial direction within the slot 12. Further, the spring member 210 is also disposed at the center portion in the axial direction of the stator core 10. Specifically, the spring member 210 is provided so as to overlap each of the plurality of contact portions 190 when viewed in the radial direction.

In addition, each of the first surface 171a and the second surface 181a is subjected to plating treatment. That is, the surfaces subjected to the plating treatment (the first surface 171a and the second surface 181a) are in contact with each other.

In the plating treatment, for example, metals such as Ni, Ag, Au, and Sn are used. Further, the plating treatment may be performed using a plurality of metals (for example, Ni and Ag) among the above metals.

As shown in fig. 28, the first leg 171 includes: a first surface arrangement portion 171b, a distal end portion 171c, a first leg main body portion 171d, and a first stepped portion 171 e. A gap 171f is provided between the first stepped portion 171e and the distal end portion 181c of the second leg portion 181. The gap 171f is an example of the "first gap" according to the invention.

In addition, the second leg portion 181 includes: a second surface disposition portion 181b, a distal end portion 181c, a second leg main body portion 181d, and a second stepped portion 181 e. A gap 181f is provided between the stepped portion 181e and the distal end portion 171c of the first leg 171. The gap portion 181f is an example of the "second gap portion" according to the invention.

The first surface arrangement portion 171b and the second surface arrangement portion 181b are provided at a central portion P3 (see fig. 27) in the axial direction of the stator core 10. In fig. 28, each of the first stepped portion 171e and the second stepped portion 181e is illustrated without having a corner inner surface having a circular shape, but each of the first stepped portion 171e and the second stepped portion 181e may have a corner inner surface having a circular shape as in the first embodiment.

As shown in fig. 29, the sheet-like insulating member 121 is provided to insulate the contact portions 190, which are formed by contacting the first leg portions 171, which expose the conductor surfaces 140b (see fig. 24), and the second leg portions 181, which expose the conductor surfaces 140b, between the coils adjacent in the radial direction in one slot 12, without using a bonding material. Specifically, the insulating members 121 are respectively provided between a plurality of coils (a group of the first leg portion 171 and the second leg portion 181 that are in contact with each other) arranged in the radial direction in the slot 12 (8 in the second embodiment).

Specifically, the insulating member 121 is formed by folding 1 sheet of insulating member such as Nomex material, for example. Further, the insulating member 121 includes: the facing surface insulating portion 121a covering the facing surface 190a of the contact portion 190 adjacent in the radial direction is continuous from both circumferential ends of the facing surface insulating portion 121a, and the circumferential surface insulating portion 121b covering at least an insulating distance from either one of the circumferential surfaces 190b of the contact portion 190 adjacent in the radial direction. The facing surfaces 190a of the contact portions 190 are radially outer and radially inner surfaces of the radially adjacent contact portions 190 that face each other. In addition, the insulation distance refers to a length along the radial direction of the circumferential surface insulation portion 121b, and refers to a sufficient distance (creeping distance) for insulating the contact portions 190 adjacent in the radial direction from each other. The circumferential surface 190b is a surface of the contact portion 190 that intersects the circumferential direction. In other words, the circumferential surface 190b refers to a surface extending in the radial and axial directions.

In addition, the insulating member 121 includes a contact insulating portion 121c formed in such a manner that the radially outer facing surface insulating portion 121a and the circumferential surface insulating portion 121b provided on one side in the circumferential direction among a pair of facing surface insulating portions 121a adjacent in the radial direction and the radially inner facing surface insulating portion 121a and the circumferential surface insulating portion 121b provided on the other side in the circumferential direction are arranged to be continuous.

The stator 200 further includes a core leg insulating portion 122 provided between the slot 12 and the coil portion 130 and integrally formed with the contact portion insulating portion 121 c. That is, the core leg portion insulating portion 122 is sheet-shaped like the contact portion insulating portion 121c, and is formed of the same material as the contact portion insulating portion 121 c. In addition, the contact portion insulating portion 121c and the core leg portion insulating portion 122 have a thickness (not shown) of the same size. In addition, the contact portion insulating portion 121c and the core foot portion insulating portion 122 have the same length in the axial direction.

Specifically, the core leg portion insulating portion 122 has a one-side insulating portion 122a that is continuous with the outermost facing surface insulating portion 121a and is provided between the slot 12 (the circumferential side surface 13a) and the coil portion 130 (the circumferential surface 190b) on one side in the circumferential direction of the slot 12 (the left side in fig. 29). Further, the core leg portion insulating portion 122 has another side insulating portion 122b which is continuous with the facing surface insulating portion 121a of the innermost diameter and is provided between the slot 12 (the circumferential side surface 13a) and the coil portion 130 (the circumferential surface 190b) on the other circumferential side (the right side in fig. 29) of the slot 12.

Specifically, as for the one-side insulating portion 122a (the other-side insulating portion 122b), a portion sandwiched by the circumferential side surface 13a of the slot 12 and the circumferential surface 190b of the coil portion 130 and a portion sandwiched by the circumferential side surface 13a of the slot 12 and the circumferential surface insulating portion 121b covering the circumferential surface 190b of the coil portion 130 alternately exist in the radial direction.

The one-side insulating portion 122a extends from the radially outer end 230a to the radially inner end 230b (extends to the end 230b) of the coil portion 130 in the slot 12. The other-side insulating portion 122b extends from the radially inner end 230b to the radially outer end 230a (over the end 230a) of the coil portion 130 in the slot 12. That is, the coil portion 130 in the slot 12 is provided so as to be surrounded by the outermost facing surface insulating portion 121a, the innermost facing surface insulating portion 121a, the one side insulating portion 122a, and the other side insulating portion 122 b.

Further, the core leg portion insulating portion 122 includes a radially inner insulating portion 122c provided so as to be continuous with the one-side insulating portion 122a and cover the opposed surface insulating portion 121a of the innermost diameter from the radially inner side. Further, the core leg portion insulating portion 122 has a radially outer insulating portion 122d provided so as to be continuous with the other-side insulating portion 122b and cover the opposed surface insulating portion 121a of the outermost diameter from the radially outer side.

Specifically, the radially inner insulating portion 122c is provided so as to be sandwiched between the innermost facing surface insulating portion 121a and the spring member 210. That is, the coil part 130 is insulated from the spring member 210 by the innermost facing surface insulating part 121a and the radially inner insulating part 122 c. The radially outer insulating portion 122d is provided so as to be sandwiched between the outermost facing surface insulating portion 121a and the wall portion 11a of the slot 12. That is, the coil portion 130 is insulated from the wall portion 11a (stator core 10) of the slot 12 by the outermost facing surface insulating portion 121a and the radially outer insulating portion 122 d.

In addition, the radially inner insulating portion 122c has a length L41 in the circumferential direction. In addition, the radially outer insulating portion 122d has a length L42 in the circumferential direction. The length L41 of the radially inner insulating portion 122c and the length L42 of the radially outer insulating portion 122d are respectively greater than, for example, 1/2 of the width W2 (refer to fig. 3) of the slot 12.

As shown in fig. 27, the contact portion insulating portion 121c and the core leg portion insulating portion 122 are arranged such that the edge portions on both sides in the axial direction protrude outward from the end surfaces (10a, 10b) of the stator core 10 in the axial direction. Thereby, each of the contact portion insulating portion 121c and the core foot portion insulating portion 122 is provided throughout the entirety of the insertion slot 12 in the axial direction.

As shown in fig. 30, the core leg portion insulating portion 122 includes: an insulating layer 123a, and a fixing layer 123b that contains a foaming agent 123c that foams due to heat, and expands by foaming the foaming agent 123c, thereby fixing each of the first leg portion 171 and the second leg portion 181 at least in the axial direction with respect to the stator core 10. The fixing layer 123b of the core leg insulating portion 122 is configured to fix each of the first leg 171 and the second leg 181 to the stator core 10 by adhesion. The fixed layer 123b is provided on both surfaces of the insulating layer 123 a. When the fixing layer 123b is heated, the thermosetting resin 123d is cured. This eliminates the need to use paint or the like for fixing each of the first leg 171 and the second leg 181. In fig. 30, the core leg insulating portion 122 is illustrated so as to have a thickness larger than the actual thickness in order to protrude. In fig. 30, the stator core 10 and the like are not shown for simplicity. Note that the insulating layer 123a and the fixed layer 123b have the same configuration (material) as the insulating layer 20a and the fixed layer 20c of the first embodiment, respectively, and thus detailed description thereof is omitted. Although not shown, the contact portion insulating portion 121c has the same configuration (composition) as the core leg portion insulating portion 122.

(Process for producing stator)

Next, a method (step) for manufacturing the stator 200 will be described with reference to fig. 31.

As shown in fig. 31, first, in step S11, the insulating member 121 (contact portion insulating portion 121c) is inserted (disposed) into the slot 12 integrally with the core leg portion insulating portion 122.

Next, in step S12, the second leg 181 (see fig. 26A and 26B) of the second conductor 180 is inserted into the slot 12 from the other axial side (the Z1 direction side).

Next, in step S13, the first leg 171 (see fig. 25A and 25B) of the first conductor 170 is inserted into the slot 12 from one axial side (the Z2 direction side). At this time, the first leg 171 is disposed such that the first surface 171a of the first leg 171 faces the second surface 181a of the second leg 181.

Next, in step S14, the spring member 210 (see fig. 27) is inserted into the slot 12 from the radially inner side through the opening 12a of the slot 12.

Also, in step S15, stator core 10 is heated and fixing layer 123b is heated, whereby foaming agent 123c foams and fixing layer 123b expands. Thereby, the coil portion 130 is fixed at least in the axial direction with respect to the slot 12.

The other configuration of the second embodiment is the same as that of the first embodiment.

[ Effect of the first and second embodiments ]

In the first and second embodiments, the following effects can be obtained.

In the first and second embodiments, as described above, the first gap portion (74, 171f) is provided between the first sector conductor (70, 170) and the second sector conductor (80, 180) joined to each other at the joint portion (90, 190), and between the tip portion (71c, 171c) of the first leg portion (71, 171) and the second leg main body portion (81d, 181d) in the axial direction. Second clearance portions (84, 181f) are provided between the tip portions (81c, 181c) of the second leg portions (81, 181) and the first leg portion main bodies (71d, 171d) in the axial direction. The term "joined" is used in a broad sense to include not only a state where the joining is performed via a bonding material (joining material), but also a state where the joining is performed only so as not to contact the bonding material (joining material).

Thus, even when dimensional variations occur during the manufacture of the first fan-shaped conductors (70, 170) and the second fan-shaped conductors (80, 180), the variations can be absorbed by the first gap portions (74, 171f) and the second gap portions (84, 181 f). As a result, the tip portions (71c, 81c, 171c, 181c) of the conductors (70, 80, 170, 180) of the first fan-shaped conductors (70, 170) and the second fan-shaped conductors (80, 180) that are relatively large in size are brought into contact with the conductors (70, 80, 170, 180) to be joined, thereby preventing axial movement of the other first fan-shaped conductors (70, 170) and the second fan-shaped conductors (80, 180) from being blocked. As a result, even in a state where the coil end portions (72, 82, 172, 182) of the first sector conductor (70, 170) and the second sector conductor (80, 180) are aligned in height, the conductor (70, 80, 170, 180) of the first sector conductor (70, 170) and the second sector conductor (80, 180) that is manufactured to have a relatively small size can be easily brought into contact with the conductor (70, 80, 170, 180) that is the object of joining at the joining portion (90, 190). Thus, even when the sizes of the first sector conductors (70, 170) and the second sector conductors (80, 180) are deviated, the protruding amounts of the coil end portions (72, 82, 172, 182) of the first sector conductors (70, 170) and the second sector conductors (80, 180) can be made uniform, and the joint areas of the first leg portions (71, 171) and the second leg portions (81, 181) can be secured.

Further, the first and second gap portions (74, 171f, 84, 181f) are provided, whereby the first sector conductor (70, 170) and the second sector conductor (80, 180) can be prevented from coming into contact in the axial direction. As a result, even when there is a conductor (70, 80, 170, 180) that is manufactured to have a size larger than the design size, among the first sector-shaped conductor (70, 170) and the second sector-shaped conductor (80, 180), the first sector-shaped conductor (70, 170) (the first leg (71, 171)) and the second sector-shaped conductor (80, 180) (the second leg (81, 181)) can be prevented from being disposed at positions that are axially outward of the predetermined positions.

Even when assembly deviation occurs when the first sector conductors (70, 170) and the second sector conductors (80, 180) are assembled, the deviation can be absorbed by the first gap portions (74, 171f) and the second gap portions (84, 181 f).

In addition, in the first and second embodiments, as described above, each of the first surface (71a, 171a) and the second surface (81a, 181a) is joined at the joint (90, 190) with respect to a part of each other. Further, the lengths (L4, L5) in the axial direction of the first surface (71a, 171a) and the second surface (81a, 181a) are greater than the length (L6) in the axial direction of the engaging portion (90, 190). With this configuration, each of the first gap portions (74, 171f) and the second gap portions (84, 181f) can be easily formed.

In addition, in the first and second embodiments, as described above, each of the first face (71a, 171a) and the second face (81a, 181a) extends in parallel with respect to the axial direction and is disposed facing each other in the radial direction. In addition, the first surfaces (71a, 171a) and the second surfaces (81a, 181a) are joined to each other in the radial direction. With this configuration, the first surfaces (71a, 171a) and the second surfaces (81a, 181a) extend in parallel to the axial direction, and therefore can be easily assembled without interfering with each other in the axial direction. In addition, since the slot (12) in which the first leg (71, 171) and the second leg (81, 181) are disposed opens in the radial direction, the first surface (71a, 171a) and the second surface (81a, 181a) engage with each other in the radial direction, and thus the engaging portion (90, 190) can be easily pressed by the pressing member (spring member 210) through the portion of the slot (12) that opens in the radial direction.

In the first and second embodiments, as described above, both the length (L7) of the first gap section (74, 171f) in the axial direction and the length (L8) of the second gap section (84, 181f) in the axial direction are greater than the thickness (t2) of the first surface arrangement section (71b, 171b) of the first leg section (71, 171) on which the first surface (71a, 171a) is provided and the thickness (t4) of the second surface arrangement section (81b, 181d) of the second leg section (81, 181) on which the second surface (81a, 181a) is provided, in the direction (radial direction) in which the first surface (71a, 171a) and the second surface (81a, 181a) are joined. With this configuration, since both the axial length (L7) of the first gap section (74, 171f) and the axial length (L8) of the second gap section (84, 181f) can be increased, the dimensional variations and assembly variations can be more reliably absorbed.

In the first and second embodiments, as described above, each of the first gap portions (74, 171f) and the second gap portions (84, 181f) is disposed in the slot (12). With this configuration, the coil portions (30, 130) can be prevented from increasing in length in the axial direction as compared with the case where each of the first gap portions (74, 171f) and the second gap portions (84, 181f) is disposed outside the slot (12).

In the first embodiment, as described above, each of the first gap portion (74) and the second gap portion (84) is provided in the vicinity of one end surface (10a) of the armature core (10) in the axial direction with respect to the center (C2) of the armature core (10) in the axial direction. With this configuration, the first surface (71a) and the second surface (81a) can be joined together in the vicinity of the one end surface (10 a). Here, since the vicinity of the one end surface (10a) is a portion through which lubricating oil passes, heat generation at the joint (90) can be cooled by the oil. In addition, since the thicknesses (t2, t4) in the direction (radial direction) in which the first surface arrangement portion (71b) of the first leg (71) on which the first surface (71a) is provided and the first surface arrangement portion (81b) of the second leg (81) on which the second surface (81a) is provided are joined to each other are relatively small, the current density is relatively high and the amount of heat generation is relatively large. Therefore, in such a configuration, it is particularly effective to join the first surface (71a) and the second surface (81a) in the vicinity of the one end surface (10a) at a point of efficiently cooling a portion where the amount of heat generation is large. The vicinity of the one end surface (10a) includes both the position itself of the one end surface (10a) and the vicinity of the one end surface (10 a).

In the first embodiment, as described above, each of the first sector conductor (70) and the second sector conductor (80) has a U-shape including the pair of first legs (71) and the pair of second legs (81). The pair of first leg portions (71) and the pair of second leg portions (81) have different lengths in the axial direction from each other. The first surfaces (71a) of the pair of first legs (71) are joined to the second surfaces (81a) of the pair of second legs (81), and the first gap (74) and the second gap (84) are provided in the vicinity of the one end surface (10 a). With this configuration, the first gap section (74) and the second gap section (84) can be easily provided in the vicinity of the end surface 10a simply by making the axial lengths of the pair of first leg sections (71) and the pair of second leg sections (81) different from each other.

In addition, in the first embodiment, as described above, the conductive adhesive (91) is applied to the portion (71e, 81e) corresponding to the joint portion (90) of at least one of the first surface (71a) and the second surface (81a), and is also applied to the portion (71i) facing the second gap portion (84) of the first surface (71a) and the portion (81i) facing the first gap portion (74) of the second surface (81a) as viewed in the direction (radial direction) in which the first surface (71a) and the second surface (81a) are joined. With this configuration, even when the first leg (71) and the second leg (81) are displaced in the axial direction from a predetermined position, the first surface (71a) and the second surface (81a) can be joined together by the conductive adhesive (91) applied to a portion (71i) of the first surface (71a) that faces the first gap (74) and a portion (81i) of the second surface (81a) that faces the second gap (84), as viewed in the joining direction (radial direction) of the first surface (71a) and the second surface (81 a). Thus, even when the first leg (71) and the second leg (81) are displaced in the axial direction from a predetermined position, the joint area between the first surface (71a) and the second surface (81a) can be ensured.

In the first and second embodiments, as described above, in one slot (12), a plurality of first surface arrangement portions (71b, 171b) of the first leg portions (71, 171) on which the first surfaces (71a, 171a) are provided and a plurality of second surface arrangement portions (81b, 181d) of the second leg portions (81, 181) on which the second surfaces (81a, 181a) are provided are alternately arranged in the radial direction. In addition, each of the first gap portion (74, 171f) and the second gap portion (84, 181f) is provided for each set of the first leg portion (71, 171) and the second leg portion (81, 181) that are joined to each other. With this configuration, the dimensional variations and the assembly variations can be absorbed by the first gap portions (74, 171f) and the second gap portions (84, 181f) in all the sets of the first leg portions (71, 171) and the second leg portions (81, 181) joined to each other in one slot (12).

In the first and second embodiments, as described above, the joint insulating member (21, 121) is provided so as to extend in the axial direction so as to cover both the first gap portion (74, 171f) and the second gap portion (84, 181f) when viewed in the radial direction. With this configuration, the adjacent joint sections (90, 190) can be prevented from being electrically connected to each other via the first gap sections (74, 171f) and the second gap sections (84, 181 f).

In addition, in the first embodiment, as described above, the first face arrangement portion (71b) is provided continuously with the first leg main body portion (71d) via the first step portion (71g), the first step portion (71g) including the corner inner surface (71f) facing the second gap portion (84) and having a circular shape. In addition, the second surface arrangement portion (81b) is provided continuously with the second leg main body portion (81d) via a second stepped portion (81g), the second stepped portion (81g) including a corner inner surface (81f) facing the first gap portion (74) and having a circular shape. With this configuration, since the corner inner surface (71f) and the corner inner surface (81f) having a circular shape are provided on the first step portion (71g) and the second step portion (81g), respectively, stress concentration on the first step portion (71g) and the second step portion (81g) can be suppressed during and after joining of the first surface (71a) and the second surface (81 a). As a result, even when the second gap portion (84) and the first gap portion (74) are provided so as to face each of the corner inner surface (71f) and the corner inner surface (81f), stress concentration at each of the first step portion (71g) and the second step portion (81g) can be suppressed, and damage to the first leg portion (71) and the second leg portion (81) can be suppressed.

In addition, in the first embodiment, as described above, each of the front end portions (71c, 171c) of the first leg portions (71, 171) and the front end portions (81c, 181c) of the second leg portions (81, 181) has a tapered shape. With this configuration, when the first leg (71, 171) and the second leg (81, 181) are inserted into the slot (12) in the axial direction so that the first surface (71a, 171a) and the second surface (81a, 181a) are joined, the distal end (71c, 171c) of the first leg (71, 171) and the distal end (81c, 181c) of the second leg 81 can be prevented from interfering with each other.

In the first and second embodiments, as described above, in the step of arranging the first sector conductor (70, 170) and the second sector conductor (80, 180), the first sector conductor (70, 170) and the second sector conductor (80, 180) are arranged such that the first gap portion (74, 171f) is provided between the tip portion (71c, 171c) of the first leg portion (71, 171) and the second leg portion (81d, 181d) in the axial direction, and the second gap portion (84, 181f) is provided between the tip portion (81c, 181c) of the second leg portion (81, 181) and the first leg portion (71d, 171d) in the axial direction.

Thus, even when dimensional variations occur during the manufacture of the first fan-shaped conductors (70, 170) and the second fan-shaped conductors (80, 180), the variations can be absorbed by the first gap portions (74, 171f) and the second gap portions (84, 181 f). As a result, the tip portions (71c, 81c, 171c, 181c) of the plurality of first sector-shaped conductors (70, 170) and second sector-shaped conductors (80, 180) that are relatively large-sized conductors can be connected to the conductors (70, 80, 170, 180) to be connected, thereby preventing axial movement of the other first sector-shaped conductors (70, 170) and second sector-shaped conductors (80, 180) from being blocked. As a result, even in a state where the coil end portions (72, 82, 172, 182) of the first sector conductor (70, 170) and the second sector conductor (80, 180) are aligned in height, the conductor (70, 80, 170, 180) of the first sector conductor (70, 170) and the second sector conductor (80, 180) that is manufactured to have a relatively small size can be easily brought into contact with the conductor (70, 80, 170, 180) that is the object of joining at the joining portion (90, 190). Thus, even when the sizes of the first sector conductors (70, 170) and the second sector conductors (80, 180) are deviated, the amount of projection of the coil end portions (72, 82, 172, 182) of the first sector conductors (70, 170) and the second sector conductors (80, 180) can be made uniform, and the joint area between the first leg portions (71, 171) and the second leg portions (81, 181) can be secured.

[ modified examples ]

The embodiments disclosed herein are merely illustrative and not intended to limit the present invention in all respects. The scope of the present invention is defined by the claims rather than the description of the above embodiments, and includes all modifications (variations) equivalent in meaning and scope to the claims.

For example, in the first and second embodiments described above, the first surface 71a (171a) and the second surface 81a (181a) are each extended in parallel with the axial direction. Each of the first surface 71a (171a) and the second surface 81a (181a) may be inclined at a predetermined angle (for example, 5 degrees or less) with respect to the axial direction.

In the first and second embodiments, the first surface 71a (171a) and the second surface 81a (181a) are joined to each other in the radial direction. The first surface 71a (171a) and the second surface 81a (181a) may be joined in a direction (e.g., circumferential direction) intersecting the radial direction.

In the first and second embodiments, the axial lengths (L7, L8) of the first gap portion 74(171f) and the second gap portion 84(181f) are both greater than the radial thicknesses (t2, t4) of the first surface arrangement portion 71b (171b) and the second surface arrangement portion 81b (181 b). One of the first gap portion 74(171f) and the second gap portion 84(181f) may have a length (L7 or L8) in the axial direction that is greater than the radial thicknesses (t2, t4) of the first surface arrangement portion 71b (171b) and the second surface arrangement portion 81b (181 b).

In the first embodiment, the first gap portion 74 and the second gap portion 84 are disposed in the slot 12, but the present invention is not limited thereto. For example, a part of the first gap portion 74 and the second gap portion 84 (for example, only the second gap portion 84) may be disposed outside the slot 12 (see fig. 32), or both the first gap portion 74 and the second gap portion 84 may be disposed entirely outside the slot 12 (see fig. 33).

In the first embodiment, the first gap portion 74 and the second gap portion 84 are disposed in the vicinity of the end surface 10a (one end surface), but the present invention is not limited to this. For example, each of the first gap portion 74 and the second gap portion 84 may be disposed in the vicinity of the end surface 10a (one end surface) and the end surface 10b (the other end surface). In this case, as shown in fig. 34, the pair of first leg portions 271 of the first sector conductor 270 are configured to have mutually different lengths (see fig. 34A), and the pair of second leg portions 281 of the second sector conductor 280 are configured to have mutually different lengths (see fig. 34B). That is, the first sector conductor 270 and the second sector conductor 280 each have a J shape (substantially J shape).

In the second embodiment, the contact portion 190 (the joint portion) is disposed near the center portion in the axial direction in the socket 12, but the present invention is not limited to this. For example, the contact portion 190 (joint portion) may be disposed in the vicinity of the end face 10a (one end face) and the end face 10b (the other end face).

In the first embodiment, the length of the second leg 81 is longer than the length of the first leg 71, but the present invention is not limited to this. For example, the length of the second leg 81 may be shorter than the length of the first leg 71. In the second embodiment, the length L31 of the first leg 171 and the length L32 of the second leg 181 may be different from each other.

In the first embodiment, the second conductor 80 having the longer leg portion is a conductor on the lead side, and the first conductor 70 having the shorter leg portion is a conductor on the reverse lead side. For example, the second conductor 80 having a long leg may be a conductor on the reverse lead side, and the first conductor 70 having a short leg may be a conductor on the lead side. In the second embodiment, the second conductor 180 may be a conductor on the reverse lead side and the first conductor 170 may be a conductor on the lead side.

In the first embodiment, the conductive adhesive 91 is applied to the entire surface portion 71i (the portion facing the second gap portion) and the entire surface portion 81i (the portion facing the first gap portion), but the present invention is not limited thereto. For example, the conductive adhesive 91 may be applied only to a part of each of the face portion 71i (the portion facing the second gap portion) and the face portion 81i (the portion facing the first gap portion). In addition, the conductive adhesive 91 may also be not applied to each of the face portion 71i (the portion facing the second gap portion) and the face portion 81i (the portion facing the first gap portion).

In the first embodiment, the corner inner surface 71f and the corner inner surface 81f have arc shapes having a radius of curvature smaller than the radial thickness t2 of the first surface arrangement portion 71b and the radial thickness t4 of the second surface arrangement portion 81b, respectively, but the present invention is not limited to this. The corner inner surface 71f and the corner inner surface 81f may have arc shapes having radii of curvature equal to or greater than the radial thickness t2 of the first surface arrangement portion 71b and the radial thickness t4 of the second surface arrangement portion 81b, respectively.

In the first embodiment, the first insulating member 20 including the fixing layer 20c configured as the adhesive layer is used, but the present invention is not limited thereto. For example, the wall portion 11a and the circumferential side surface 13a may be fixed to the second leg portion 81 by pressing them together (pressing force) without adhesion using the first insulating member 20 including an expansion material (expansion layer) different from the adhesive layer. The second embodiment may be configured in the same manner.

In the above-described embodiment, the first insulating member 20 and the second insulating member 21 (joint insulating member) are sheet-shaped, but the present invention is not limited thereto. The present invention can also be applied to a stator having the first insulating member 20 and the second insulating member 21 which are not in a sheet shape. Similarly, each of the insulating member 121 (joint insulating member) and the core leg insulating portion 122 of the second embodiment may not be formed in a sheet shape.

Description of the reference numerals

10 … stator core (armature core); 10a … end face (one side end face); 10b … end face (other side end face); 12 … slot; 21 … second insulating member (joint insulating member); 30. 130 … coil section; 40. 140 … sector conductor; 70. 170, 270 … a first conductor; 71. 171, 271 … first leg; 71a, 171a … first face; 71b, 171b … first surface arrangement parts; 71c, 171c … (the front end of the first leg); 71d, 171d … first leg body portion; 71f … corner inner surface (corner inner surface of first step portion); 71g … first step; 71i … face portions (portions facing the second gap portions); 74. 171f … first gap portion; 80. 180 … a second conductor; 81. 181 … a second foot; 81a, 181a … second face; 81b, 181b … second surface arrangement part; front ends 81c and 181c … (front ends of the second leg portions); 81d, 181d … second leg body portions; 81f … corner inner surface (corner inner surface of second step portion); 81g … second step; an 81i … face portion (portion facing the first gap portion); 84. 181f … second gap portion; a 90 … joint; 91 … conductive adhesive; 100. 200 … stator (armature); 121 … insulating member (joint insulating member); 190 … contact portion (engagement portion); c2 … axial center (center); l1 … length (length of first leg); l2 … length (length of second foot); l4 … length (length of first face); l5 … length (length of second face); l6 … length (length of joint); l7 … length (length of first gap portion); l8 … length (length of second gap portion); t2 … thickness (thickness of first surface arrangement portion); t3 … thickness (thickness of first leg main body portion); t4 … thickness (thickness of second surface arrangement portion); t5 … thickness (thickness of the second leg main body portion).