JP2000078804A - Manufacture of stator molded with resin for brushless electric motor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a stator molded with a resin for a brushless electric motor which makes it possible to secure high quality and to reduce the number of parts and working hours. SOLUTION: The end of a winding is wound from the bottom of a terminal pin 4 toward its top up to a given position 4a of the terminal pin 4. A locking part 3b for this end of the winding is soldered. After the terminal pin 4 is forced into a given position again, the top end part of the winding-end locking part 3b is pushed with a mold-forming die 7 to expose the end part 4b of the terminal pin. Then, a stator core 1, a stator winding 3, an insulator 2 and the winding-end locking part 3b are encased with a resin and solidified to manufacture a resin-molded stator. By manufacture the resin-molded stator this way, the leakage of the resin and the breaking of the winding-end can be prevented. Furthermore, since a protective member which is required in a conventional art can be eliminated, the number of parts can be reduced without deteriorating quality, and a manufacturing method of resin-molded stator for a brushless electric motor by which the working hours can be cut is obtainable.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a resin-molded stator for a brushless motor, which is one of small motors mainly used as a blower fan driving source for a room air conditioner, a water heater or the like.

[0002]

2. Description of the Related Art In recent years, resin mold stators of this type of brushless motors have been required to have high quality because of their low cost, reduced number of parts, and high quality. Above, there is a strong demand to pursue a reduction in working time.

Conventionally, a method of manufacturing a resin mold stator for this type of brushless motor will be described with reference to FIGS.

[0004] As shown in the figure, a stator core 51 having a plurality of slots is integrally molded or sandwiched in the axial direction by an insulator 52 to insulate the stator core 51, and a terminal pin 54 is pre-pressed into the insulator 52. After that, the stator winding 53 is directly wound. After winding,
The winding terminal 53a of the stator winding 53 is engaged with a terminal pin 54 for connection to an external board (not shown), and is soldered or fused. Here, the terminal pins 54 are press-fitted, and subsequently, the ends of the terminal pins 54 are exposed to cover the winding terminals 53a and the soldered or fusing portions, so that resin leakage during molding of the resin and the winding terminals 53a can be prevented. A protective member 55 for preventing disconnection is covered, and a molding die 57
The protective member 55 is pressed by a part 57a of the protective member 55, the mold resin 56 is injected into the molding die 57, and the distal ends of the stator core 51, the insulator 52, the stator winding 53 and the terminal pins 54 are exposed. 55 is integrally molded and solidified to form a resin mold stator of the brushless motor.

[0005]

In such a conventional method of manufacturing a resin mold stator for a brushless electric motor, burrs occur due to resin leakage from terminal pins 54 for connection to an external substrate during resin molding. In addition, since it is necessary to cover the protection member 55 so as not to impair the quality such as disconnection of the winding terminal 53a, the number of parts increases,
There is a problem that the working time increases, and it is required to ensure high quality and reduce the number of parts and the working time.

SUMMARY OF THE INVENTION The present invention is to solve such a conventional problem, and to provide a method of manufacturing a resin mold stator of a brushless electric motor which can ensure high quality and reduce the number of parts and the working time. With the goal.

[0007]

According to a first aspect of the present invention, there is provided a brushless motor comprising: a stator core having a plurality of slots; and an insulator for insulating the stator core. A multi-phase stator winding wound directly on the stator core through the insulator,
A plurality of terminal pins for locking the terminals of the stator winding and connecting them by soldering, and terminal pin holding means for fixing the terminal pins are provided on the insulator, exposing the tip of the terminal pins, In a resin mold stator obtained by integrally molding and solidifying a stator core and the stator winding with resin, after winding the stator winding on the stator core, a terminal of the stator winding is formed. Is wound up from the bottom of the terminal pin and locked, and soldered. Then, the upper end of the winding terminal locking portion is pressed with a mold, and the tip of the terminal pin is exposed and resin molded. This is a method for manufacturing a resin mold stator for a brushless motor.

Thus, a method for manufacturing a resin mold stator for a brushless motor can be obtained in which the number of parts can be reduced and the working time can be reduced without deteriorating the quality.

In order to achieve the above object, a second means is to wind the terminal of the stator winding upward from a lower position of the terminal pin to a predetermined position, and then lower the terminal pin to engage the terminal pin. Then, after soldering, the upper end of the winding terminal locking portion is pressed by a mold, and the tip of the terminal pin is exposed to perform resin molding, thereby producing a resin-molded stator of a brushless motor. .

Thus, a method of manufacturing a resin mold stator for a brushless motor can be obtained in which high quality can be ensured, the number of parts can be reduced, and working time can be reduced.

In order to achieve the above object, a third means is that the terminal pins are in a pre-press-fitted state until resin molding, and the upper end of the winding terminal locking portion is molded with a mold at the time of resin molding. At the same time as pressing down and re-pressing with mold clamping,
According to another aspect of the present invention, there is provided a method of manufacturing a resin-molded stator of a brushless motor in which a tip of the terminal pin is exposed and resin-molded.

As a result, a method of manufacturing a resin mold stator for a brushless motor can be obtained in which high quality can be ensured, the number of parts can be reduced, and the working time can be reduced.

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS According to the first aspect of the present invention, a terminal of a stator winding is wound up from the bottom of a terminal pin and locked and soldered. A method of manufacturing a resin-molded stator for a brushless motor in which the upper end of a locking portion is pressed with a mold and the tip of a terminal pin is exposed and resin-molded. This prevents resin leakage during resin molding and disconnects winding terminals. Has the effect of preventing

According to a second aspect of the present invention, the terminal of the stator winding is wound up from a lower position of the terminal pin to a predetermined position, and then wound down, locked and soldered. A method for manufacturing a resin-molded stator of a brushless motor in which the upper end of the winding terminal locking portion is pressed with a mold, and the tip of the terminal pin is exposed and resin-molded. This has the effect of reliably preventing resin leakage and disconnection of winding terminals at the time of resin molding, even if the thickness becomes smaller.

According to a third aspect of the present invention, the terminal pins are in a pre-pressed state until resin molding is performed, and the upper end of the winding end locking portion is pressed by a mold during resin molding, and the terminal is clamped. A method of manufacturing a resin-molded stator of a brushless motor in which the tip of the terminal pin is exposed and resin-molded at the same time as press-fitting. Without changing the number of windings and the like to be locked to the pins, it has the effect of reliably eliminating resin leakage and disconnection of winding terminals during resin molding and eliminating the step of re-press-fitting the terminal pins.

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

[0017]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS (Embodiment 1) As shown in FIGS. 1 to 4, 1 is a stator core having a plurality of slots, and 2 is an insulator for insulating the stator winding 3 and the stator core 1. The stator core 1 is integrally formed. Reference numeral 4 denotes a terminal pin for connecting to an external printed circuit board (not shown) and for connecting the winding terminal 3a.
A hole 6 as a terminal pin holding means for press-fitting is opened. Reference numeral 5 denotes a molding resin such as unsaturated polyester, and reference numeral 7 denotes a molding die for molding the stator core.

In the above configuration, after the terminal pins 4 are pre-press-fitted into the holes 6 of the insulator 2, the stator winding 3 is wound by a winding machine, and the winding end 3a is cut to a predetermined length. Terminal 3a on terminal pin 4 by wire wrapper
Lock. At this time, the winding terminal 3a is wound up from the bottom of the terminal pin 4 to a predetermined position 4a of the terminal pin 4. Subsequently, the winding terminal locking portion 3b is soldered by a solder robot, and the terminal pins 4 are press-fitted to a predetermined position again, and are set in the mold 7. Then, the upper end 3d of the winding terminal locking portion 3b is pressed by the part 7a of the molding die 7, and the molding resin 5 is injected into the molding die 7, exposing the tip 4b of the terminal pin. The stator core 1, the stator winding 3, the insulator 2, and the winding end locking portion 3 b are integrally molded and solidified to manufacture the resin mold stator 8.

According to such a method of manufacturing a resin mold stator for a brushless motor of the present invention, at the time of molding,
Since a part 7a of the molding die 7 presses the upper end 3d of the winding terminal locking portion 3b of the terminal pin 4, the molding is performed.
Since the winding end 3a between the winding winding portion 3c and the terminal pin 4 is not pressed by the mold, it is possible to prevent resin leakage and disconnection of the winding end. In addition, it is possible to eliminate a protection member that is conventionally required. As a result, it is possible to obtain a method of manufacturing a resin mold stator for a brushless electric motor in which the number of parts can be reduced and the working time can be reduced without deteriorating quality.

(Embodiment 2) As shown in FIG. 5, the winding terminal 3a is wound up from a lower portion of the terminal pin 4 to a predetermined position 4a of the terminal pin 4, and then unwound and doubled. Locked. Subsequently, the winding end locking portion 3e is soldered by a solder robot, the terminal pins 4 are re-pressed to a predetermined position, and the terminal pins 4 are set in the mold 7. Then, the upper end 3f of the winding terminal locking portion 3e is pressed by a part 7a of the molding die 7, the molding resin 5 is injected into the molding die 7, and the tip 4b of the terminal pin is exposed. The stator core 1, the stator winding 2, the insulator 3, and the winding end locking portion 3 e are integrally molded and solidified to manufacture the resin mold stator 8.

According to the method of manufacturing a resin mold stator for a brushless motor according to the present invention, at the time of molding,
Since the winding end 3a of the terminal pin 4 is pressed by the part 7a of the molding die 7 to hold the upper end 3f of the winding end locking portion 3e which is double locked, the stator winding is formed. Even if the wire diameter of the wire 3 becomes small, it is possible to reliably prevent resin leakage and disconnection of the winding terminal. In addition, it is possible to eliminate a protection member that is conventionally required. As a result, it is possible to obtain a method of manufacturing a resin mold stator for a brushless electric motor, which can reduce the number of parts and the work time while ensuring high quality.

(Embodiment 3) As shown in FIGS. 6 and 7, the terminal pins 4 are in a pre-pressed state, the gap 9 is made large to some extent, the stator winding 3 is wound, and the winding terminal 3a is a terminal. Predetermined position 4 of terminal pin 4 from bottom to top of pin
After being wound up to a, it is rolled down and locked double. Subsequently, the winding end locking portion 3e is soldered by a solder robot, and is set in the mold 7. Then, the upper end portion 3f of the winding end locking portion 3e is pressed by a part 7a of the molding die 7 and clamped. At this time,
Terminal pin 4 is re-pressed. Then, the molding resin 5 is injected into the molding die 7, and the tip 4b of the terminal pin is formed.
Are exposed and the stator core 1, stator windings 3, insulators 2, and winding end locking portions 3e are integrally molded and solidified to manufacture the resin mold stator 8.

According to the method of manufacturing a resin mold stator for a brushless motor of the present invention, at the time of molding,
At a part of the molding die 7, the upper end portion 3 of the winding terminal locking portion 3e in which the winding terminal 3a of the terminal pin 4 is double locked.
Since the mold is held down by pressing f and the terminal pin 4 is re-pressed and molded at the same time, even if the wire diameter of the stator winding 3 is different, the setting of the mold and the number of turns to be locked to the terminal pin 4 are changed. Therefore, it is possible to reliably prevent resin leakage and disconnection of winding terminals. Further, even if the press-fit variation of the terminal pin 4 or the position of the winding terminal locking portion is slightly shifted in the axial direction, resin leakage and disconnection of the winding terminal can be prevented. Further, the step of re-press-fitting the protection member and the terminal pin 4 which was conventionally required can be eliminated. As a result, it is possible to obtain a method of manufacturing a resin mold stator for a brushless electric motor, which can reduce the number of parts and the work time while ensuring high quality.

[0024]

As is clear from the above embodiments, according to the present invention, the ends of the stator windings are wound up from the bottom of the terminal pins and locked, soldered, and then wound. By holding the upper end of the wire terminal locking part with a mold, exposing the tip of the terminal pin and resin molding, the winding terminal between the winding part and the terminal pin is not pressed by the mold, Prevents resin leakage during resin molding and disconnection of winding terminals, thus reducing the number of parts without reducing quality, shortening the working time, and reducing the cost of resin mold stator for brushless motors. Can be provided.

Further, after winding up the terminal of the stator winding upward from the bottom of the terminal pin to a predetermined position, lowering the terminal winding, locking and soldering, the upper end of the winding terminal locking portion By pressing the portion with a mold and exposing the tip of the terminal pin and performing resin molding, even if the wire diameter of the stator winding is reduced, it is possible to reliably prevent resin leakage and disconnection of the winding terminal during resin molding. Therefore, high quality can be ensured, the number of parts can be reduced, the operation time can be reduced, and a method of manufacturing a resin mold stator for a low-cost brushless motor can be provided.

The terminal pins are kept in a pre-pressed state until resin molding. At the time of resin molding, the upper end of the winding terminal locking portion is pressed with a mold and re-pressed by mold clamping. By exposing the tip and resin molding, even if the wire diameter of the stator winding is different, without changing the mold setting or the number of turns to be locked to the terminal pin, etc.
Resin leakage and disconnection of winding terminals can be reliably prevented, and resin leakage and disconnection of winding terminals can be prevented even if the terminal pin press-fit variation and the position of the winding terminal locking portion are slightly shifted in the axial direction. A method for manufacturing a resin mold stator of a low-cost brushless motor that can reduce the number of parts and further reduce the work time while ensuring quality can be provided.

[Brief description of the drawings]

FIG. 1 is a detailed sectional view of a main part showing a state during resin molding by a method of manufacturing a resin mold stator of a brushless motor according to a first embodiment of the present invention.

FIG. 2 is a perspective view showing a stator core of the brushless motor after the insulator is installed.

FIG. 3 is a perspective view showing a stator core after winding the stator windings;

FIG. 4 is a perspective view showing a stator after the resin molding.

FIG. 5 is a detailed sectional view of a main part showing a state at the time of resin molding according to the second embodiment.

FIG. 6 is a detailed sectional view of a main part of the third embodiment before mold clamping.

FIG. 7 is a detailed sectional view of a main part after the same mold is clamped.

FIG. 8 is a detailed sectional view of a main part of a resin mold stator of a conventional brushless motor.

FIG. 9 is an exploded perspective view showing a stator before resin molding of the brushless motor.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Stator core 2 Insulator 3 Stator winding 3a Winding terminal 3b Winding terminal locking part 3c Winding winding part 3d Upper end 3e Winding terminal locking part 3f Upper end 4 Terminal pin 4a Predetermined position of terminal pin 4b Tip of terminal pin 5 Mold resin 6 Hole 7 Mold mold 7a Part of mold mold 8 Resin mold stator 9 Clearance

Claims (3)

[Claims] 1. A stator core having a plurality of slots, an insulator for insulating the stator core, and a multi-phase stator winding wound directly on the stator core via the insulator. A plurality of terminal pins for locking the ends of the stator windings and connecting them by soldering, and a terminal pin holding means for fixing the terminal pins are provided on the insulator, exposing the ends of the terminal pins, In a resin mold stator obtained by integrally molding and solidifying the stator core and the stator winding with resin, after winding the stator winding on the stator core, After winding the terminal upward from the bottom of the terminal pin and locking it, and soldering, the upper end of the winding terminal locking portion is pressed with a mold, and the tip of the terminal pin is exposed to form a resin mold. Brushless electric The method for producing a resin molded stator. 2. The terminal of the stator winding is wound up from a position below the terminal pin to a predetermined position, and then wound down and locked and soldered. A method of manufacturing a resin-molded stator of a brushless motor in which an upper end portion is pressed with a mold, and a tip of the terminal pin is exposed to perform resin molding. 3. The method for manufacturing a resin mold stator according to claim 1, wherein the terminal pins are pre-press-fitted until resin molding, and are re-pressed by mold clamping during resin molding. .