Stator, brushless motor, stator manufacturing method

Abstract

A stator includes: plural core configuration sections each including plural yoke configuration sections that configure a ring shaped yoke and are segmented in a yoke circumferential direction and plural teeth sections that project from the respective yoke configuration sections along a yoke radial direction, with the plural yoke configuration sections and the plural teeth sections integrated together; plural coil wires that are wound onto the respective teeth sections to configure plural winding portions; and plural insulators that each include plural insulator portions that are integrated to each of the respective core configuration sections and insulate between the teeth sections and the winding portions, and a connection portion that connects together the plural insulator portions.

What is claimed is: 
     
         1 . A stator comprising:
 a plurality of core configuration sections each comprising a plurality of yoke configuration sections that configure a ring shaped yoke and are segmented in a yoke circumferential direction and a plurality of teeth sections that project from the respective yoke configuration sections along a radial direction of the yoke, with the plurality of yoke configuration sections and the plurality of teeth sections integrated together;   a plurality of coil wires that are wound onto the respective teeth sections to configure a plurality of winding portions; and   a plurality of insulators that each includes a plurality of insulator portions that are integrated to each of the respective core configuration sections and insulate between the teeth sections and the winding portions, and a connection portion that connects together the plurality of insulator portions.   
     
     
         2 . The stator of  claim 1 , wherein the plurality of coil wires configure a plurality of phases. 
     
     
         3 . The stator of  claim 2  wherein:
 each of the coil wires includes a plurality of crossing wires that connect together the plurality of winding portions and are laid out at the connection portion; 
 the plurality of connection portions are disposed with a gap between each other in one direction out of the yoke radial direction, a yoke axial direction, or in a direction that is a combination thereof; and 
 a housing portion is formed to at least one connection portion out of the plurality of connection portions for housing a member. 
 
     
     
         4 . The stator of  claim 3  wherein:
 each of the coil wires includes a plurality of crossing wires that connect together the plurality of winding portions and are laid out at at least one of the plurality of connection portions; and 
 each of the connection portions includes a retaining portion that retains the plurality of crossing wires laid out at the connection portion. 
 
     
     
         5 . The stator of  claim 4  wherein:
 the plurality of connection portions are disposed with a gap between each other in a yoke radial direction; and 
 at least one of the plurality of connection portions includes a spacer provided between the plurality of connection portions in the yoke radial direction and retaining the plurality of connection portions in a state separated from each other in the yoke radial direction. 
 
     
     
         6 . The stator of  claim 4  wherein:
 the plurality of connection portions are disposed with a gap between each other in a yoke axial direction; 
 at least one of the plurality of connection portions includes a spacer provided between the plurality of connection portions in the yoke axial direction and retaining the plurality of connection portions in a state separated from each other in the yoke axial direction. 
 
     
     
         7 . The stator of  claim 6 , wherein the plurality of connection portions are provided coaxially to the yoke. 
     
     
         8 . The stator of  claim 3 , wherein the member is a crossing wire out of the plurality of crossing wires, the crossing wire is laid out on the different connection portion form the connection portion having the housing portion. 
     
     
         9 . The stator of  claim 4 , wherein the retaining portion is formed in a projection shape. 
     
     
         10 . The stator of  claim 5 , wherein the spacer is formed in a projection shape. 
     
     
         11 . The stator of  claim 10 , wherein the connection portion is positioned further to the yoke radial direction inside than the core configuration section. 
     
     
         12 . The stator of  claim 11  wherein:
 the insulator portions of at least one of the plurality of insulators includes insulator main body portions that are integrated to the respective core configuration sections and insulate between the teeth sections and the winding portions, and extending portions that are positioned further to the yoke radial direction inside than the core configuration sections and extend from the insulator main body portions in one direction out of the yoke axial direction, radial direction, or circumferential direction, or a direction that is a combination thereof; and 
 the connection portion connects together the extending portions of the plurality of insulator portions. 
 
     
     
         13 . The stator of  claim 12  wherein:
 the insulator portion includes a first insulator portion and a second insulator portion, the first insulator portion and the second insulator portion each including a teeth section insulator portion and a yoke configuration section insulator portion respectively covering the teeth section and the yoke configuration section. 
 
     
     
         14 . The stator of  claim 1  further comprising a terminal station that is provided to each of the plurality of insulators and that connects to a terminal portion of each of the plurality of coil wires. 
     
     
         15 . The stator of  claim 14  wherein:
 the connection portion is positioned at the yoke radial direction inside; and 
 a projection portion is formed to an end portion of at least one insulator portion out of the plurality of insulator portions at an opposite side to a yoke side, the projection portion projecting out to the yoke side with respect to the connection portion; and 
 the terminal station is provided at the projection portion. 
 
     
     
         16 . The stator of  claim 15  wherein:
 an insertion groove is formed at the projection portion so as to open towards the yoke axial direction; and 
 the terminal station is inserted into the insertion groove. 
 
     
     
         17 . The stator of  claim 15  wherein:
 the connection portion is disposed displaced in the yoke axial direction with respect to the plurality of insulator portions; and 
 the terminal station makes contact with a surface on the yoke side of the connection portion. 
 
     
     
         18 . The stator of  claim 14  wherein:
 each of the plurality of coil wires includes a crossing wire that connects together the plurality of winding portions and that is laid out displaced in a yoke axial direction with respect to the insulator portion; and 
 the terminal station is provided on the yoke axial direction opposite side to the crossing wires. 
 
     
     
         19 . The stator of  claim 14  further comprising a guide portion that is formed along the yoke axial direction to each of the plurality of insulators and that guides the terminal portion of each of the plurality of coil wires. 
     
     
         20 . The stator of  claim 19 , wherein the guide portion is provided to a side face of the projection portion. 
     
     
         21 . The stator of  claim 14 , wherein one of the plurality of yoke configuration sections is provided with a terminal station that connects to a terminal portion of each of the plurality of coil wires. 
     
     
         22 . The stator of  claim 1  further comprising a second connection portion that is separated in a stator core axial direction from the connection portion, that is formed at at least one insulator out of the plurality of insulators, and that connects together the plurality of insulator portions of the at least one insulator. 
     
     
         23 . The stator of  claim 22  wherein:
 the connection portion is disposed at a first side in the stator core axial direction; 
 the second connection portion is formed at the insulator positioned furthest to a second side in the stator core axial direction out of the plurality of insulators when the plurality of insulators are in a pre-assembly state arranged along the stator core axial direction. 
 
     
     
         24 . The stator of  claim 22  wherein:
 the plurality of connection portions are disposed coaxially to each other and have different external diameters to each other; and 
 the second connection portion is formed to the insulator with the connection portion of the smallest external diameter out of the plurality of insulators. 
 
     
     
         25 . The stator of  claim 24  wherein:
 the second connection portion connects together a plurality of the extending portions of one of the insulators. 
 
     
     
         26 . The stator of  claim 25 , wherein the plurality of insulators have an interlocking structure for positioning with respect to each other, the interlocking structure comprising:
 a fitting portion formed at the second connection portion; and   a fitted-to portion that fits together with the fitting portion and is formed to an insulator portion positioned between a pair of insulator portions connected by the second connection portion out of the plurality of insulator portions.   
     
     
         27 . The stator of  claim 26  wherein:
 the insulator portion includes a first insulator portion and a second insulator portion segmented in the stator core axial direction; 
 the connection portion connects together the plurality of first insulator portions of each of the insulators; and 
 the second connection portion connects together the plurality of first insulator portions in one of the insulators. 
 
     
     
         28 . The stator of  claim 26  wherein:
 the insulator portion includes a first insulator portion and a second insulator portion segmented in the stator core axial direction; 
 the connection portion connects together the plurality of first insulator portions of each of the insulators; and 
 the second connection portion connects together a plurality of the second insulator portions in one of the insulators. 
 
     
     
         29 . The stator of  claim 1  wherein:
 the insulators have an interlocking structure for positioning with respect to each other; 
 the core configuration member includes a teeth section extending along the stator core radial direction and a yoke configuration section formed to a leading end portion of the teeth section; 
 the plurality of insulator portions each includes a yoke configuration section insulator portion that covers the yoke configuration section; and 
 the interlocking structure comprises
 a fitting portion formed to a first of adjacent of the yoke configuration section insulator portions, and 
 a fitted-to portion that fits together with the fitting portion and is formed to a second of the adjacent yoke configuration section insulator portions. 
 
 
     
     
         30 . The stator of  claim 1  further comprising an interlocking structure that fixes the plurality of connection portions together. 
     
     
         31 . The stator of  claim 1  wherein:
 a plurality of independently formed groups of stator configuration sections are configured by assembling the plurality of core configuration sections to the respective plurality of insulators; 
 in each of the plurality of stator configuration section groups, the plurality of core configuration sections are disposed so as to form a gap corresponding to at least one core configuration section between adjacent core configuration sections; 
 the plurality of stator configuration section groups are disposed such that in a mutually assembled state a core configuration section of another group is disposed in the gap; and 
 each of the plurality of coil wires is formed continuously from end-to-end and includes a crossing wire that connects together the plurality of winding portions. 
 
     
     
         32 . The stator of  claim 31  wherein:
 out of the crossing wires, at least one of the crossing wires connected to a winding start end portion of the winding portion and one of the crossing wires connected to a winding finish end portion of the winding portion cross over at a connection vicinity between the connection portion and the insulator portion. 
 
     
     
         33 . The stator of  claim 32  wherein:
 each of the insulator portions includes an insulator main body portion that is integrated to the core configuration section and insulates between the teeth section and the winding portion, and an extending portion that connects together the insulator main body portion and the connection portion; and 
 a radial direction extension portion is formed to the extending portion so as to extend in a radial direction of the stator configuration section from the connection portion; and 
 an intersection portion between the crossing wire connected to the winding start end portion of the winding portion and the crossing wire connected to the winding finish end portion of the winding portion is disposed at a position that overlaps with the radial direction extension portion as viewed along the stator configuration section axial direction. 
 
     
     
         34 . The stator of  claim 32  wherein:
 each of the insulator portions includes an insulator main body portion that is integrated to the core configuration section and insulates between the teeth section and the winding portion, and an extending portion that connects together the insulator main body portion and the connection portion; and 
 an axial direction extension portion is formed to the extending portion so as to extend in an axial direction of the stator configuration section from the connection portion; and 
 an intersection portion between the crossing wire connected to the winding start end portion of the winding portion and the crossing wire connected to the winding finish end portion of the winding portion is disposed at a position that overlaps with the axial direction extension portion as viewed along the stator configuration section radial direction. 
 
     
     
         35 . The stator of  claim 1 , wherein the teeth section projects from the yoke configuration section towards the yoke radial direction inside. 
     
     
         36 . The stator of  claim 35  wherein:
 the insulator portion includes an extension side wall portion that extends along an axial direction of the stator configuration section; and 
 in each of the plurality of stator configuration section groups, with respect to an imaginary line extending in a tangential direction to the stator configuration section so as to pass through the extension side wall portion, an end in the circumferential direction of the yoke configuration section of a first core configuration section is positioned so as to be on the opposite side to a second core configuration section disposed adjacent to the first core configuration section with the imaginary line being positioned between the first and second core configuration sections. 
 
     
     
         37 . The stator of  claim 34 , wherein the teeth sections project from the yoke configuration section towards the yoke radial direction outside. 
     
     
         38 . The stator of  claim 37 , wherein the adjacent yoke configuration sections are fitted together with recess and protrusion shaped fitting portions. 
     
     
         39 . The stator of  claim 38 , wherein the winding portions are compression deformed by pressing. 
     
     
         40 . The stator of  claim 39  wherein:
 each of the plurality of stator configuration section groups is configured by a combination of mutually different phases; 
 in each of the stator configuration sections, the plurality of teeth sections are disposed at even intervals from each other; and 
 out of the plurality of winding portions, a pair of winding portions that face each other across a stator configuration section axis are formed from the same coil wire and are formed by winding in reverse directions to each other. 
 
     
     
         41 . The stator of  claim 40  wherein:
 a winding portion wound in a loosening direction on the teeth section out of the pair of winding portions and a crossing wire between the pair of winding portions are connected together by a lead portion that is led out from the teeth section; 
 a protrusion portion to which the lead portion is anchored is formed to the insulator; and 
 the winding portion wound in a loosening direction on the teeth section out of the pair of winding portions is restricted from slackening by the lead portion being anchored to the protrusion portion. 
 
     
     
         42 . A brushless motor comprising:
 the stator according to  claim 1 ; and   a rotor that rotates in a rotational magnetic field generated by the stator.   
     
     
         43 . A brushless motor comprising:
 the stator according to  claim 22 ; and   a rotor that rotates in a rotational magnetic field generated by the stator.   
     
     
         44 . A brushless motor comprising:
 the stator according to  claim 31 ; and   a rotor that rotates in a rotational magnetic field generated by the stator.   
     
     
         45 . A manufacturing method for a stator of  claim 1 , the stator manufacturing method comprising:
 a sub-assembly forming process in which the core configuration sections are integrated to the insulator portions of each of the insulators to form a sub-assembly for each of a plurality of groups;   a stator configuration section forming process in which the stator configuration sections are formed for each of the plurality of groups by winding the coil wire on each of the teeth sections of each of the sub-assemblies from a radial direction outside of the stator configuration section using a coil wire winding machine; and   a stator forming process that forms a stator by assembling the plurality of stator configuration sections together.   
     
     
         46 . The stator manufacturing method of  claim 45  further comprising, between the stator configuration section forming process and the stator forming process, a compression process that presses and compression deforms the winding portions in each of the plurality of stator configuration section groups. 
     
     
         47 . The stator manufacturing method of  claim 46 , wherein in the compression process the winding portions are pressed from a direction orthogonal to a teeth section axial direction. 
     
     
         48 . The stator manufacturing method of  claim 46 , wherein in the compression process the winding portions are pressed from both sides of a direction orthogonal to the teeth section axial direction. 
     
     
         49 . The stator manufacturing method of  claim 46 , wherein in the compression process the winding portions are pressed such that the pressing direction on the winding portions is a tangential direction to the respective stator configuration section. 
     
     
         50 . A stator manufacturing method comprising:
 an installation and cutoff process that employs an insulator in which a plurality of first insulator portions, second insulator portions, and bridging sections have been integrated together and each of the bridging sections connects together the first insulator portion and the second insulator portion, that installs a core configuration section for forming a stator core to one portion out of the first insulator portion and the second insulator portion, and that cuts off the bridging sections;   a positional alignment process that performs positional alignment between the other portion out of the first insulator portion and the second insulator portion and the core configuration section by moving at least one portion out of the first insulator portion and the second insulator portion with respect to the other portion;   an installation process that installs the other portion out of the first insulator portion and the second insulator portion to the core configuration section; and   a coil wire winding process that forms a coil wire winding portion with a coil wire at the core configuration section by winding the coil wire on the core configuration section with the first insulator portion and the second insulator portion interposed therebetween.   
     
     
         51 . The stator manufacturing method of  claim 50 , wherein in the installation and cutoff process, the bridging section is cut off after the core configuration section has been installed to the one portion out of the first insulator portion and the second insulator portion. 
     
     
         52 . The stator manufacturing method of  claim 50 , wherein, as the insulator, the first insulator portion and the second insulator portion each respectively include a teeth section insulator portion and a yoke configuration section insulator portion that respectively cover a teeth section and a yoke configuration section formed to the core configuration section, and the bridging section connects together the yoke configuration section insulator portions of the first insulator portion and the second insulator portion.