JP2011234537A - Bobbin for rotating electric machine, manufacturing method of rotating electric machine and bobbin for the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a bobbin for a rotating electric machine, manufacturing method of a rotating electric machine and bobbin for the same capable of enhancing the space factor of a cable.SOLUTION: A bobbin for a rotating electric machine 21, which is fitted into a tooth part 18 of a stator core 15, comprises: a trunk 22 which has a cylindrically shape and is made of a insulation member; a first flange 23 and a second flange 24 which are made of synthetic resins and integrally provided at both ends of the trunk 22. The trunk 22 has a portion which is provided with a insulator film at least inside the stator core 15 and is integrated with the first flange 23 and the second flange 24 by insert molding.

Description

  The present invention relates to a rotating electrical machine bobbin that fits into a tooth portion of a stator core of a rotating electrical machine, a rotating electrical machine, and a method of manufacturing the rotating electrical machine bobbin.

Rotating electric machines such as electric motors and generators are mounted on hybrid vehicles and electric vehicles. A stator of this type of rotating electrical machine has, for example, a stator core and a coil provided by concentrated winding on a tooth portion of the stator core, as shown in Patent Document 1. The coil is formed by winding an electric wire around the outer periphery of a bobbin for a rotating electrical machine, and is provided in the tooth part by fitting the bobbin for the rotating electrical machine to a tooth part.
In general, a bobbin for a rotating electrical machine includes a barrel portion that has a cylindrical shape and an electric wire is wound around the outer periphery thereof, and flange portions that are provided at both axial end portions of the barrel portion. The trunk portion and the collar portion are made of synthetic resin, and are integrally molded by, for example, injection molding.

JP 2008-167598 A

In recent years, in order to increase the output and efficiency of rotating electrical machines, it has been studied to further increase the line area ratio (space factor) of electric wires provided in the teeth portion of the stator core. As a method for increasing the line area ratio of an electric wire, for example, it is considered that the body portion of a bobbin for a rotating electrical machine is thinned so that the thinned body volume is occupied by the electric wire (coil).
However, when the body of a bobbin for a rotating electrical machine is molded by injection molding as in the conventional manufacturing method, if the body is made too thin, the body may crack after injection molding. It was not possible to reduce the thickness, and the line area ratio of the wires could not be sufficiently increased.

  Accordingly, the present invention has been made in view of the above problems, and an object thereof is to provide a bobbin for a rotating electrical machine, a rotating electrical machine, and a method for manufacturing the bobbin for a rotating electrical machine that can increase the line area ratio of an electric wire. That is.

  In order to achieve the above-described object, the bobbin for a rotating electrical machine according to the present invention is made of a synthetic resin integrally provided at both ends of an insulating material body having a cylindrical shape and an electric wire wound around the outer periphery. A bobbin for a rotating electrical machine that is fitted into a teeth portion of a stator core, and at least a portion located in the stator core is formed of an insulating film, and the flange portion is formed by insert molding. It is characterized in that it is integrated.

  A rotating electrical machine according to the present invention is provided on a stator having a stator core, a bobbin for a rotating electrical machine according to claim 1 or 2 provided on the stator core, and an inner periphery or an outer periphery of the stator core. It is characterized by having a rotor.

  Furthermore, the bobbin for a rotating electrical machine according to the present invention includes a cylindrical body made of an insulating material in which an electric wire is wound around an outer periphery, and a flange portion made of a synthetic resin integrally provided at both ends of the cylindrical body. In a method for manufacturing a bobbin for a rotating electrical machine that is fitted to a tooth portion of a stator core, a body shaping step for shaping an insulating film constituting at least a portion of the body located in the stator core into a predetermined shape And a flange forming step of forming a flange having the body portion integrally by placing the shaped insulating film in an insert molding die and performing insert molding. Yes.

  According to the present invention, since at least a portion of the body portion of the bobbin for a rotating electrical machine that is fitted into the teeth portion of the stator core is located in the stator core, the insulating core is formed in the stator core in the body portion. A portion to be positioned can be made thinner than the conventional configuration, and many electric wires can be wound around a bobbin for a rotating electrical machine, thereby increasing the line area ratio of the electric wires. Therefore, a rotating electrical machine with high output and high efficiency can be obtained.

  Further, according to the present invention, the insulating film constituting the portion located in the stator core is shaped into a predetermined shape, and the shaped insulating film is placed in the insert molding die to perform insert molding. Therefore, it is possible to obtain a bobbin for a rotating electrical machine that includes a body portion in which at least a portion located in the stator core is made of an insulating film.

The cross-sectional top view which shows the state after the bobbin for rotary electric machines of 1st Embodiment of this invention was fitted to the stator core. A view of the state after the bobbin for rotating electrical machines is fitted to the stator core as seen from the center side of the stator core Sectional drawing which follows the AA line of FIG. Sectional drawing which follows the BB line of FIG. Transverse plan view showing the state before the rotating electrical machine bobbin is fitted to the stator core Perspective view of bobbin for rotating electrical machine Right side view Plan view Sectional drawing which follows the CC line of FIG. Sectional drawing which follows the DD line of FIG. The figure which shows the manufacturing process of the bobbin for rotary electric machines schematically It is a figure which shows the line area ratio of an electric wire, (a) is a vertical side view for demonstrating the line area ratio of the electric wire at the time of using the bobbin for rotary electric machines of this embodiment, (b) is the rotary electric machine of a conventional structure. Longitudinal side view for explaining the line area ratio of electric wires when using bobbins A longitudinal side view showing a bobbin for a rotating electrical machine according to a second embodiment of the present invention. Sectional drawing which follows the EE line of FIG. FIG. 13 equivalent view showing a bobbin for a rotating electrical machine according to a third embodiment of the present invention. Sectional drawing which follows the FF line of FIG. Transverse plan view showing a state before a bobbin for a rotating electrical machine according to a fourth embodiment of the present invention is fitted into a stator core Plan view of bobbin for rotating electrical machines The perspective view of the bobbin for rotary electric machines is shown, (a) is a view before the first bobbin piece and the second bobbin piece are combined, and (b) is the combination of the first bobbin piece and the second bobbin piece. Figure of state after FIG. 9 equivalent view before the first bobbin piece and the second bobbin piece are aligned. Figure 7 equivalent figure before bobbin pieces for rotating electrical machines are matched

  Hereinafter, a plurality of embodiments of the present invention are applied to a rotating electric machine such as an inner rotor type electric motor and a generator used in a hybrid vehicle and an electric vehicle, and will be described with reference to the drawings. In the drawings, the front and rear, the left and right, and the top and bottom directions are appropriately indicated by arrows, and for convenience, the axial direction of the rotating electrical machine will be described as the vertical direction. Moreover, in each embodiment, the same reference number is attached | subjected about the part which is the same or it corresponds, and the description is abbreviate | omitted.

(First embodiment)
First, a first embodiment will be described with reference to FIGS.
1 to 4 show an enlarged view of a portion of the rotating electrical machine 11. As shown in FIG. 1, the rotating electrical machine 11 includes a stator 12 and a rotor 13 provided on the inner peripheral side of the stator 12 via a gap.
The rotor 13 has a rotor core 14 and a permanent magnet (not shown) embedded in the rotor core 14. The rotor core 14 has a cylindrical shape. A shaft (not shown) is provided on the inner peripheral portion of the rotor core 14.

  The stator 12 has a stator core 15 and a coil 16. The stator core 15 has a cylindrical yoke portion 17 and a plurality of teeth portions 18 protruding from the inner peripheral surface of the yoke portion 17 to the inner peripheral side of the yoke portion 17, that is, the central axis side ( Only one tooth portion 18 is shown in FIG. The yoke portion 17 is not completely circular on the outer periphery, and various shapes such as an ellipse and a polygon can be employed. The teeth part 18 is formed in the substantially rectangular parallelepiped as shown in FIGS. Further, by arranging the tooth portions 18 at equal intervals in the circumferential direction of the stator core 15, as shown in FIGS. 1 and 5, between the teeth portions 18, 18 adjacent in the circumferential direction of the stator core 15. A slot 15a is formed.

  The coil 16 is configured by winding an electric wire such as a copper wire around an outer periphery of a body portion 22 of a bobbin 21 for a rotating electrical machine described later. In the first embodiment, as shown in FIG. 5, the rotating electrical machine bobbin 21 provided with the coil 16 is fitted into the teeth portion 18 from the inner peripheral side of the stator core 15 (see the direction of the arrow X in FIG. 5). ), The coil 16 is provided on the tooth portion 18 in a concentrated manner via the body portion 22 of the bobbin 21 for the rotating electrical machine.

As shown in FIGS. 1 to 10, the rotating electrical machine bobbin 21 includes a body portion 22, a first flange portion 23, and a second flange portion 24.
The trunk | drum 22 comprises cylindrical shape, for example, a rectangular tube shape, for example, as shown in FIGS. 6-10, is comprised from the upper side wall 22a, the lower side wall 22b, the right side wall 22c, and the left side wall 22d. A space 21 a that is surrounded by the upper side wall 22 a, the lower side wall 22 b, the right side wall 22 c, and the left side wall 22 d and formed on the inner periphery substantially matches the shape of the tooth portion 18. As shown in FIGS. 2 to 4, the upper side wall 22 a and the lower side wall 22 b are located outside the axial direction (up and down) ends of the stator core 15 when the bobbin 21 for rotating electrical machines is fitted to the tooth portion 18. Each part is located. Further, the right side wall 22 c and the left side wall 22 d are portions that are located in the stator core 15, that is, in the slots 15 a of the stator core 15 when the rotating electrical machine bobbin 21 is fitted to the tooth portion 18.

Here, the upper side wall 22a, the lower side wall 22b, the right side wall 22c, and the left side wall 22d are made of an insulating material, for example, an insulating film. This insulating film is preferably an insulating film, for example, a film made of a general-purpose insulating material, or a film made of a laminated insulating material. In particular, an aramid paper such as Nomex (registered trademark) manufactured by Du Pont of the United States and a product made by Toray It is preferable to use a laminated insulating material obtained by laminating PPS Torelina (registered trademark). As other film materials, it is preferable to appropriately select a polyimide film, a polyether ether ketone film, a polyethylene terephthalate film, or the like according to the purpose. The thickness of the insulating film (T ₁ shown in FIG. 12) is 0.1 to ₁ mm, preferably 0.2 to 0.3 mm. The body portion 22 is integrated with the first flange portion 23 and the second flange portion 24 by insert molding described later.

The first flange portion 23 and the second flange portion 24 function as a restriction portion that prevents the coil 16 provided in the body portion 22 from shifting in the radial direction (front-rear direction) of the stator core 15.
The first flange portion 23 has a frame shape, the body portion 22 is positioned at the inner peripheral edge, and one end portion in the axial direction of the body portion 22 (the bobbin 21 for rotating electrical machines is fitted to the teeth portion 18). It is sometimes provided at the end of the stator core 15 located on the yoke portion 17 side, that is, the rear end of the trunk portion 22.

  The second flange portion 24 has a frame shape, the body portion 22 is located at the inner peripheral edge, and the other end portion in the axial direction of the body portion 22 (the bobbin 21 for rotating electrical machines is fitted to the teeth portion 18). It is sometimes provided at the end located on the inner peripheral side of the stator core 15, that is, the front end of the body 22. The second flange 24 is positioned closer to the inner peripheral side of the stator core 15 than the first flange 23 so that the second flange 24 adjacent in the circumferential direction of the stator core 15 does not hit. The length of the stator core 15 in the circumferential direction (left-right direction) is preferably shorter than the length of the first flange 23 in the circumferential direction. Furthermore, the surface on the rotor 13 side of the surface of the second flange portion 24 may be formed in a curved shape that swells toward the trunk portion 22 when viewed from the plane direction. Further, the surface on the stator core 15 side of the surface of the first flange portion 23 may be curved so as to contact the inner peripheral surface of the yoke portion 17 of the stator core 15. Positioning of the bobbin 21 for the rotating electrical machine is facilitated by the first flange portion 23 coming into contact with the inner peripheral surface of the yoke portion 17.

The first flange portion 23 and the second flange portion 24 are made of synthetic resin, such as PPS resin (polyphenylene sulfide resin), acrylonitrile / butadiene / styrene copolymer resin, polyimide resin, polyethylene terephthalate resin, polyacetal resin, and the like. It is preferable that it is molded with. The first flange 23 and the second flange 24 are formed by insert molding (injection molding) described later. The thicknesses of the first flange 23 and the second flange 24 formed by insert molding (the thickness of the first flange 23 of the bobbin 21 for a rotating electrical machine schematically shown in FIG. The thickness is indicated by T ₂ ) is arbitrary, but is, for example, 2 to 3 mm. Incidentally, the thickness T ₂ of the first flange portion 23 and the second flange portion 24 is made smaller in a range capable of insert molding, correspondingly, the width direction of the body portion 22 of the rotary electric machine bobbin 21 (longitudinal direction) The length of the electric wire wound around the body portion 22 may be increased to increase the line area ratio of the electric wire.

Next, an insert molding die 31 used for the insert molding is shown in FIG.
The insert molding die 31 includes a base portion 32, a lower die 33 provided on the base portion 32, and an upper die 34 provided on the lower die 33.

  The base portion 32 holds the lower die 33 and the upper die 34. Further, the base portion 32 is provided with a rectangular column block portion 35 for positioning the body portion 22 of the bobbin 21 for the rotating electrical machine. The block part 35 has substantially the same shape as the tooth part 18 of the stator core 15. The base portion 32 has a plurality of projecting pins 36 projecting upward. The protruding pins 36 are for removing the rotating electrical machine bobbin 21 formed by insert molding in the lower mold 33 described later from the lower mold 33.

  The lower mold 33 is composed of a pair of block-shaped movable lower molds 37, 37. The pair of movable lower dies 37, 37 is on the base portion 32 and is configured to slide on the upper surface of the base portion 32 so that the die can be opened (see the arrow Y direction in FIG. 11C). Each movable lower die 37 is formed with cutouts 38 ′ and 38 ′ (see FIG. 11 (d)) that are substantially half the shape of the rotating electrical machine bobbin 21. By combining the movable lower dies 37, 37, A cavity 38 (see FIG. 11 (f)) for accommodating the rotating electrical machine bobbin 21 is formed.

  A nozzle 39 that communicates from the upper surface of the movable lower die 37 to the cavity 38 is formed on the upper portion of the movable lower die 37. The nozzle 39 is a passage for supplying a molten resin (not shown) (for example, a melted PPS resin) (not shown) for forming the first flange portion 23 and the second flange portion 24 from the upper mold 34 to the cavity 38. .

  The upper die 34 is for supplying the molten resin to the nozzle 39 of the lower die 33 as described above, and the entire upper portion 34 is formed in a block shape, and a spool runner 40 penetrating in the vertical direction of the upper die 34 is formed. ing. A storage portion 41 is formed at the upper end portion of the spool runner 40 (the upper surface of the upper mold 34). The storage part 41 is for storing the molten resin supplied from the outside. The upper die 34 is configured to be attached to the upper surface of the lower die 33. Then, by combining the upper mold 34 and the lower mold 33, the lower end portion of the spool runner 40 communicates with the nozzle 39.

Next, a manufacturing procedure of the rotating electrical machine bobbin 21 using the insert molding die 31 will be described with reference to FIG.
First, as shown to Fig.11 (a), the insulating film which comprises the trunk | drum 22 (it attaches | subjects the code | symbol 42 to an insulating film only in FIG. 11) is cut | judged to the dimension which expand | deployed the trunk | drum 22 (cutting process). In the first embodiment, the film-like insulating film 42 is cut into a rectangle. Specifically, the length P (long side length) of one side of the insulating film 42 is the length of the upper side wall 22a in the left-right direction, the length of the left side wall 22d in the vertical direction, and the length of the lower side wall 22b. It is the length obtained by adding the length of the glue margin to the total of the length in the direction and the length in the vertical direction of the right side wall 22c as necessary. The length Q (short side length) of the other side is the length in the front-rear direction of the body portion 22 (for example, the front-rear direction of the upper side wall 22a). The thickness of the insulating film 42 is, for example, 0.2 to 0.3 mm.

  Next, as shown in FIG.11 (b), the cut | disconnected insulating film 42 is bent and shape | molded in a trunk | drum shape (torso part shaping | molding process). In the first embodiment, the insulating film 42 obtained in the cutting step is bent into a rectangular tube shape. When the size (length) of the insulating film 42 includes the length of the adhesive margin, when the insulating film 42 is bent into a rectangular tube shape, the portion of the adhesive margin is located on the upper side wall 22a or the lower side wall 22b. Is preferred. Further, in the body shaping step, an adhesive or the like is applied to the glue margin, and the insulating film 42 is temporarily fixed in a rectangular tube shape before the insert molding to prevent the insulating film 42 from being out of shape during the insert molding. You may do it.

  Next, as shown in FIGS. 11 (c) and 11 (d), the lower mold 33 is folded into a rectangular tube shape with the mold open (the movable lower molds 37, 37 are separated). The insulating film 42 (body portion 22) is fitted into a predetermined position of the insert molding die 31, that is, the block portion 35 of the base portion 32 (body portion arranging step). When the insulating film 42 is fitted into the block portion 35, it is preferable that the insulating film 42 is slightly separated from the base portion 32. Thereby, after insert molding, the edge part located in the base part 32 side among the edge parts of the front-back direction (axial direction) of insulating film 42 is the collar part (the 1st collar part 23, the 1st collar part) formed by insert molding. Located inside the second flange 24).

Next, as shown in FIG. 11 (e), the movable lower molds 37, 37 are joined together to form the cavity 38 of the bobbin 21 for the rotating electrical machine in the lower mold 33 (lower mold fixing step).
Next, as shown in FIG. 11 (f), the upper die 34 is attached to the upper surface of the lower die 33. Then, molten resin is injected into the storage portion 41 of the upper mold 34. The resin injected into the storage portion 41 is supplied to the cavity 38 through the spool liner 40 and the nozzle 39, whereby insert molding is performed, and the first flange portion 23 and the first flange portion integrated with the body portion 22. The second collar part 24 is molded (a collar part molding step).

  After the insert molding, the upper mold 34 is removed from the lower mold 33, the movable lower molds 37, 37 of the lower mold 33 are opened, and the projecting pins 36 of the base section 32 project from the upper surface of the base section 32, thereby The rotating electrical machine bobbin 21 is removed from the portion 32.

Next, a procedure for attaching the coil 16 to the tooth portion 18 of the stator core 15 will be described with reference to FIGS. 1, 5, and 10.
First, an electric wire is wound around the outer periphery of the body portion 22 of the bobbin 21 for a rotating electrical machine shown in FIG. 10, and the coil 16 is provided on the outer periphery of the body portion 22 as shown in FIG. Next, the rotating electrical machine bobbin 21 provided with the coil 16 is fitted into the teeth portion 18 of the stator core 15 from the inner peripheral side of the stator core 15 (see the arrow X direction in FIG. 5). Thereby, the coil 16 concentratedly wound around the tooth portion 18 is provided via the bobbin 21 for the rotating electrical machine. At this time, as shown in FIG. 1, the right side wall 22 c and the left side wall 22 d made of an insulating film are positioned at least in the stator core 15 of the body portion 22, and the upper side wall is formed on the outer side in the axial direction of the stator core 15. 22a and the lower side wall 22b are located.

  Similarly to the above, the rotating electric machine bobbin 21 provided with the coil 16 is fitted into the teeth portion 18 of the stator core 15 in the other teeth portion 18 of the stator core 15. As a result, the coils 16 are provided in all the teeth portions 18 of the stator core 15.

Next, the effect of the above configuration will be described.
According to the first embodiment, the right side wall 22c and the left side wall 22d, which are at least portions of the body portion 22 of the rotating electrical machine bobbin 21 fitted in the teeth portion 18 of the stator core 15, are located in the stator core 15. It is composed of an insulating film. Therefore, the portions (the right side wall 22c and the left side wall 22d) located in the stator core 15 in the trunk portion 22 can be made thinner than the conventional configuration constituted by injection molding, and many electric wires can be used for bobbins for rotating electrical machines. It can be wound around 21 body portions 22. Thereby, in the structure of 1st Embodiment, the line area ratio of an electric wire can be raised rather than the conventional structure. As a result, it is possible to obtain the rotating electrical machine 11 with high output and high efficiency.

The line product ratio of the electric wire will be examined in detail with reference to FIG. FIG. 12 schematically shows a cross section of the rotating electrical machine bobbin 21 (see FIG. 12A) of the first embodiment and a cross section of the conventional rotating electrical machine bobbin 101 (see FIG. 12B). A bobbin 101 for a rotating electrical machine having a conventional configuration is obtained by integrally molding a body portion 102, a first flange portion 103, and a second flange portion 104 by injection molding. In this case, since the barrel portion 102 is molded by injection molding, the thickness T ₀ of the portion located in the stator core in the barrel portion 102 is at least a dimension that does not cause cracking after injection molding, for example, T ₀ = 1 to 1 3 mm.

On the other hand, in 1st Embodiment, since the part (the right side wall 22c and the left side wall 22d) located in the stator core 15 at least among the trunk | drum 22 is comprised from the insulating film, of the trunk | drum 22 of this embodiment. The thickness T ₁ can be set to be equal to or less than the thickness T ₀ of the trunk portion 102 having the conventional configuration. Therefore, in the first embodiment, the line product ratio of the electric wires can be made higher than the conventional configuration by an amount corresponding to (T ₀ -T ₁ ).

In general, when the current I (A) flows through the circular coil conductor, the magnetic flux density B at the axial center O of the coil is “B = μ ₀ Nl / 2r (where μ ₀ is the vacuum permeability and N is The number of turns per meter, l is the length of the coil, and r is the radius of the coil). The portion located in the stator core 15 of the body portion 22 of the first embodiment is thinner than the portion located in the stator core 15 of the body portion 102 of the above-described conventional configuration, and therefore provided on the outer periphery of the body portion 22. The radius r _{1 of the} coil 16 to be obtained can be made smaller than the radius r ₀ of the conventional coil by an amount corresponding to (T ₀ -T ₁ ). In the first embodiment, the magnetic flux density of the coil 16 is smaller than that of the conventional configuration. Can be high. Therefore, the rotation efficiency of the rotating electrical machine 11 can be improved from the viewpoint of magnetic flux density.

  In the manufacturing method of the first embodiment, as described above, the insulating film constituting the portions (the right side wall 22c and the left side wall 22d) located in the stator core 15 has a predetermined shape (in the first embodiment, a rectangular tube shape). The insulating film thus shaped is placed in the insert molding die 31 and insert molding is performed. Therefore, in the manufacturing method according to the first embodiment, a bobbin 21 for a rotating electrical machine including a body portion 22 in which at least portions (the right side wall 22c and the left side wall 22d) located in the stator core 15 are made of an insulating film is obtained. Can do.

(Second Embodiment)
Next, a second embodiment of the present invention will be described with reference to FIGS.
A bobbin 51 for a rotating electrical machine of the second embodiment shown in FIGS. 13 and 14 includes a reinforcing connecting portion 52 in addition to the body portion 22, the first flange portion 23, and the second flange portion 24 of the first embodiment. ing.
The connecting portion 52 is a side wall that connects the first flange portion 23 and the second flange portion 24, and is provided integrally with the first flange portion 23 and the second flange portion 24. The connecting portions 52 are respectively provided on the outer peripheral side (upper side) of the upper side wall 22a and on the outer peripheral side (lower side) of the lower side wall 22b.

  The bobbin 51 for a rotating electrical machine is formed by insert molding as in the first embodiment, and the connecting portion 52 is formed integrally with the first flange portion 23 and the second flange portion 24 during the insert molding. The thickness of the connecting portion 52 is arbitrary as long as it can be formed by insert molding, and is, for example, 1 to 3 mm.

According to the second embodiment, since the connecting portion 52 larger than the thickness of the trunk portion 22 is provided between the first collar portion 23 and the second collar portion 24, the strength of the trunk portion 22, particularly the trunk portion 22. The strength against compression in the axial direction (front-rear direction) increases, and deformation of the body portion 22 can be prevented. Thereby, 2nd Embodiment can obtain the bobbin 51 for rotary electric machines which has intensity | strength than 1st Embodiment.
Further, the connecting portion 52 is provided on the outer peripheral side (upper side) of the upper side wall 22a and the outer peripheral side (lower side) of the lower side wall 22b, and the right side wall 22c and the left side wall 22d are made of an insulating film. The portion located in the stator core 15 of 22 is thin, and the line area ratio of the electric wire can be made higher than that of the bobbin for a rotating electrical machine having a conventional configuration (see FIG. 11B).
In addition, the second embodiment has the same effects as the first embodiment.

Next, a third embodiment of the present invention will be described with reference to FIG. 14 and FIG.
A bobbin 61 for a rotating electrical machine of the third embodiment shown in FIGS. 15 and 16 includes a reinforcing connecting portion 62 in addition to the body portion 22, the first flange portion 23, and the second flange portion 24 of the first embodiment. ing.
The connecting portion 62 is a side wall that connects the first flange portion 23 and the second flange portion 24, and is provided integrally with the first flange portion 23 and the second flange portion 24. The connecting portion 62 is provided on the inner peripheral side (lower side) of the upper side wall 22a and on the inner peripheral side (upper side) of the lower side wall 22b.

The bobbin 61 for a rotating electrical machine is formed by insert molding as in the first embodiment, and the connecting portion 62 is formed integrally with the first flange portion 23 and the second flange portion 24 at the time of insert molding. The thickness of the connecting portion 62 is arbitrary as long as it can be formed by insert molding, and is, for example, 1 to 3 mm.
According to 3rd Embodiment, there exists an effect similar to 2nd Embodiment.

Next, a fourth embodiment of the present invention will be described with reference to FIGS.
The bobbin 71 for a rotating electrical machine according to the fourth embodiment shown in FIGS. 17 to 21 has an outer periphery of the stator core 15 ′ when the shape of the teeth 18 ′ of the stator core 15 ′ shown in FIG. It is provided in a taper shape having a width dimension on the inner peripheral side larger than a width dimension on the side. As shown in FIGS. 17 and 18, the rotating electrical machine bobbin 71 is formed with a space 71 a having the same shape as the tooth portion 18 ′ when viewed from the planar direction. The space 71a corresponds to the space 21a of the first embodiment. That is, the barrel portion 22 of the fourth embodiment is a tapered rectangular tube whose opening area on the second flange portion 24 side is larger than the opening area of the first flange portion 23 so that the teeth portion 18 ′ is fitted on the inner periphery. It has a shape.

  As shown in FIGS. 19 to 21, the rotating electrical machine bobbin 71 includes a first bobbin piece 72 and a second bobbin piece 73. The 1st bobbin piece 72 and the 2nd bobbin piece 73 are the structures which divided | segmented the rotary electric machine bobbin 71 into two substantially. The location where the bobbin 71 for rotating electrical machines is divided is arbitrary, but in the fourth embodiment, the center in the vertical direction of the right side wall 22c (see FIG. 9) and the center in the vertical direction of the left side wall 22d (see FIG. 9). A configuration when divided in step will be described.

As shown in FIGS. 19 to 21, the first bobbin piece 72 includes one end-side body piece 74, one end-side first collar piece 75, one end-side second collar piece 76, and one end-side connecting portion 77. And have.
The one end side body piece 74 is U-shaped and has the configuration of the upper half of the body portion 22 (see FIGS. 6 and 9) of the first embodiment, and specifically, shown in FIGS. 6 and 9. It is comprised from the upper side wall 22a, the upper half of the right side wall 22c, and the upper half of the left side wall 22d.

The one end side first collar part 75 is U-shaped and has the configuration of the upper half of the first collar part 23 (see FIGS. 6 and 9) of the first embodiment.
The one end side second collar part 76 is U-shaped and has the configuration of the upper half of the second collar part 24 (see FIGS. 6 and 9) of the first embodiment.

  The one end side connection part 77 is provided in the front-end | tip part by the side of the 2nd bobbin piece 73 in the 1st bobbin piece 72. FIG. The one end side connecting portion 77 has a shape in which the one end side body portion piece 74, the one end side first flange portion piece 75, and the one end side second flange portion piece 76 each extend downward, that is, a protruding shape. Here, a portion of the one end side connecting portion 77 extending from the one end side first collar piece 75 is formed thinner than the one end side first collar portion 75. Specifically, as shown in FIG. 21, a portion of the one end side connecting portion 77 extending from the one end side first collar piece 75 has a stepped shape in which the axially outer side (front side) is recessed. Further, a portion of the one end side connecting portion 77 extending from the one end side second collar portion 76 is formed thinner than the one end side second collar portion piece 76. Specifically, a portion of the one end side connecting portion 77 extending from the one end side second flange piece 76 has a stepped shape in which the outer side in the axial direction (rear side) is recessed.

The second bobbin piece 73 includes, as shown in FIGS. 19 to 21, the other end side body part piece 78, the other end side first collar part piece 79, the other end side second collar part piece 80, and the other end. Side connection portion 81.
The other end side body part piece 78 is U-shaped, and has the configuration of the lower half of the body part 22 (see FIGS. 6 and 9) of the first embodiment. The lower wall 22b shown, the lower half of the right side wall 22c, and the lower half of the left side wall 22d are configured.

The other end side first collar part 79 is U-shaped and has a lower half configuration of the first collar part 23 (see FIGS. 6 and 9) of the first embodiment.
The other end side second collar part 80 is U-shaped and has the configuration of the lower half of the second collar part 24 (see FIGS. 6 and 9) of the first embodiment.

  The other end side connecting portion 81 is provided at the tip end portion of the second bobbin piece 73 on the first bobbin piece 72 side. The other end side connecting portion 81 has a shape in which the other end side trunk portion piece 78, the other end side first flange portion piece 79, and the other end side second flange portion piece 80 respectively extend upward, that is, a protruding shape. It is. Here, the portion of the other end side connecting portion 81 that extends from the other end side first flange portion 79 is formed thinner than the other end side first flange portion 79. Specifically, as shown in FIG. 21, the portion of the other end side connecting portion 81 that extends from the other end side first collar piece 79 has a stepped shape in which the other end side second collar piece 80 side is recessed. ing. Further, a portion of the other end side connecting portion 81 extending from the other end side second collar piece 80 is formed thinner than the other end side second collar portion piece 80. Specifically, a portion of the other end side connecting portion 81 extending from the other end side second collar piece 80 has a stepped shape in which the other end side first collar portion 79 side is recessed.

  In the above configuration, the portion extending from the one end side first flange portion 75 of the one end side connecting portion 77 and the portion extending from the other end side first flange portion 79 of the other end side connecting portion 81 are matched, The side connecting portion 77 is configured to match the portion extending from the one end side second collar portion piece 76 and the portion of the other end side connecting portion 81 extending from the other end side second collar portion piece 80. The first hook part 23 of the first embodiment is formed by combining the one end side first hook part piece 75 and the other end side first hook part piece 79, and the one end side second hook part piece 76 and the other end side. By combining the second flange part piece 80, the second flange part 24 of the first embodiment is formed. In addition, when the one end side connecting portion 77 and the other end side connecting portion 81 are combined, the one end side body portion piece 74 and the other end side body portion piece 78 overlap with each other because of the small thickness, and as described above, In this case, the body 22 substantially the same as that of the first embodiment is formed.

Next, the manufacturing procedure of the bobbin 71 for rotating electrical machines using an insert molding die (not shown) will be described.
The rotating electrical machine bobbin 71 of the fourth embodiment is also formed by insert molding in the same manner as the rotating electrical machine bobbin 21 (see FIG. 1) of the first embodiment. That is, in the fourth embodiment, the first bobbin piece 72 and the second bobbin piece 73 are formed by insert molding, and after the insert molding, the first bobbin piece 72 and the second bobbin piece 73 are combined to form a bobbin for a rotating electrical machine. 71 is formed. Since the 1st bobbin piece 72 and the 2nd bobbin piece 73 are shape | molded by the same manufacturing method, only the manufacturing procedure of the 1st bobbin piece 72 is demonstrated.

In 4th Embodiment, the insulating film which comprises the one end side trunk | drum piece 74 is first cut to the dimension which expand | deployed the one end side trunk | drum piece 74 (cutting process).
Next, the cut insulating film is bent to form a substantially U-shape (U-shape), that is, one end side body piece 74 (body shaping step).

  Next, the folded insulating film is placed at a predetermined position of an insert molding die (not shown) (body placement step), for example, placed so as to surround three surfaces of the block portion 35 shown in FIG. According to the three outer peripheral surfaces of 35, it is fixed in the insert molding die (lower die fixing step). In this case, the cavity formed in the lower mold 33 has the same shape as the first bobbin piece 72.

Next, insert molding is performed. Thereby, the 1st bobbin piece 72 which the one end side trunk | drum piece 74, the one end side first collar part piece 75, the one end side second collar part piece 76, and the one end side connection part 77 were united is shape | molded. The
The second bobbin piece 73 is also obtained by insert molding similar to the first bobbin piece 72 described above. In the second bobbin piece 73, the other end side body portion piece 78, the other end side first flange portion piece 79, the other end side second flange portion piece 80, and the other end side connecting portion 81 are integrated. Yes.

  The formed first bobbin piece 72 and second bobbin piece 73 are provided on the stator core 15 so as to sandwich the teeth portion 18 ′ from both sides in the axial direction (vertical direction) of the stator core 15. A coil 16 (see FIG. 1) is formed on the body 22 by winding an electric wire around the outer periphery of the body 22 of the bobbin 71 for the rotating electrical machine provided in the tooth portion 18 '. It is provided on the teeth portion 18 ′ via the bobbin 71.

According to the fourth embodiment, as in the first embodiment, at least a portion of the body portion 22 of the bobbin 71 for a rotating electrical machine that is fitted into the tooth portion 18 ′ of the stator core 15 is located in the stator core 15. Is the insulating film of the body 22. Therefore, the portion of the body 22 located in the stator core 15 can be made thinner than the conventional configuration, and many electric wires can be wound around the bobbin 71 for the rotating electrical machine. High efficiency can be achieved.
Furthermore, in the fourth embodiment, when the shape of the teeth portion 18 ′ is a tapered shape having a width dimension on the inner peripheral side larger than a width dimension on the outer peripheral side of the stator core 15 ′ when viewed from the plane direction, A bobbin 71 for a rotating electrical machine and a coil 16 can be provided on the tooth portion 18 '.

The present invention is not limited to the embodiment described above and shown in the drawings, and the following modifications and expansions are possible.
In the first to fourth embodiments, the upper side wall, the lower side wall, the right side wall, and the left side wall of the trunk portion have been described as being formed of an insulating film, but at least the right side wall that is a portion located in the stator core, The left side wall should just be comprised with the insulating film. In this case, the upper side wall and the lower side wall may be provided integrally with the first and second collar parts using the same material as the first and second collar parts.

  In the first to fourth embodiments, the inner rotor type has been described. However, the rotating electric machine bobbin can be applied to an outer rotor type rotating electric machine, that is, a configuration in which the rotor is provided on the outer periphery of the stator. In the case of an outer rotor type rotating electrical machine, a tooth portion is located on the outer peripheral side of the stator core, and a bobbin for the rotating electrical machine is provided on this tooth portion. Further, in the fourth embodiment, the shape of the teeth part is straight when viewed from the plane direction, the taper shape is smaller in the width dimension on the inner circumference side than the width dimension on the outer circumference side of the stator core, and the tip of the teeth part is the anchor shape. It is applicable also to the structure which is.

In 2nd Embodiment and 3rd Embodiment, although the shape of the connection parts 52 and 62 was demonstrated as a side wall, the shape of the connection parts 52 and 62 is arbitrary, For example, a some column shape may be sufficient.
In the fourth embodiment, the bobbin for a rotating electrical machine has a configuration that can be divided in the vertical direction, but may be configured so that it can be divided in the horizontal direction. Moreover, although the division of the bobbin for a rotating electrical machine has been described as being divided into two, it can also be applied to a division of three or more.
The above-described embodiment is merely an example, and the material and thickness of the insulating film are determined as appropriate depending on the use of the rotating electrical machine, and the material, shape, position of the connecting portion, and the like can be changed as appropriate.

  In the drawings, 11 is a rotating electrical machine, 12 is a stator, 13 is a rotor, 15 and 15 'are stator cores, 18 and 18' are teeth portions, 21, 51, 61 and 71 are bobbins for rotating electrical machines, and 22 is A body part, 23 is a first collar part (saddle part), 24 is a second collar part (saddle part), 31 is an insert molding die, 42 is an insulating film, and 52 and 62 are joint parts.

Claims (4)

A body of insulating material that has a cylindrical shape and an electric wire is wound around the outer periphery;
A bobbin for a rotating electrical machine comprising a flange portion made of synthetic resin integrally provided at both ends of the body portion, and fitted into a teeth portion of a stator core;
A bobbin for a rotating electrical machine, wherein at least a portion located in the stator core is made of an insulating film, and the body portion is integrated with the flange portion by insert molding.   In the body portion, at least a part of the inner peripheral surface or the outer peripheral surface of the insulating film located outside the stator core is provided with a synthetic resin reinforcing connecting portion that connects between the two flange portions. The bobbin for a rotating electrical machine according to claim 1, wherein the bobbin is provided integrally with the part. A stator having a stator core;
The bobbin for a rotating electrical machine according to claim 1 or 2, provided on a teeth portion of the stator core,
A rotating electrical machine comprising: a rotor provided on an inner periphery or an outer periphery of the stator core. A rotating electric machine comprising a cylindrical body made of an insulating material in which an electric wire is wound around the outer periphery, and a synthetic resin flange provided integrally at both ends of the cylindrical body, and fitted into a teeth portion of a stator core In the bobbin manufacturing method,
A body shaping step for shaping the insulating film constituting at least a portion of the body located in the stator core into a predetermined shape;
Rotating, characterized in that the shaped insulating film is placed in an insert molding die and insert molding is performed to perform a collar molding step of molding a collar having the body portion integrally therewith. Manufacturing method of bobbin for electric machine.

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