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, each including a plurality of insulator portions and a connection portion that connects together the plurality of insulator portions, the plurality of insulator portions being integrated with respective core configuration sections and insulating the teeth sections from the winding portions, wherein:   a plurality of independently formed groups of stator configuration sections are configured by assembling the plurality of core configuration sections with 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 each gap;   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; and   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.   
     
     
         2 . The stator of  claim 1 , wherein:
 each of the insulator portions includes an insulator main body portion, that is integrated with the core configuration section and insulates the teeth section from 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 at 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.   
     
     
         3 . The stator of  claim 1 , wherein:
 each of the insulator portions includes an insulator main body portion, that is integrated with the core configuration section and insulates the teeth section from 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 at 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.   
     
     
         4 . The stator of  claim 1 , wherein the teeth section projects from the yoke configuration section towards the yoke radial direction inner side.