MOTOR STATOR AND STATOR MANUFACTURING METHOD

• US 20090302694A1
• Filed: 10/30/2007
• Published: 12/10/2009
• Est. Priority Date: 12/21/2006
• Status: Active Grant

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Asai, Masataka
• Granted Patent: US 8,063,518 B2
• Time in Patent Office: Days
• US Class Current: 310/45
• CPC Class Codes: H02K 1/148 Sectional cores H02K1/141 takes precedence
• CPC Class Codes: H02K 15/12 Impregnating, heating or drying of windings, stators, rotors or machines
• CPC Class Codes: H02K 3/18 Windings for salient poles
• CPC Class Codes: H02K 3/325 for windings on salient poles, such as claw-shaped poles
• CPC Class Codes: H02K 9/223 Heat bridges
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine

Abstract

A motor stator includes a plurality of stator cores constituted of divided cores and cassette coils which are conductive coils. One of the divided core and the cassette coil is integrally formed with an insulator of a thermosetting resin by insert molding. A stator assembly including the plurality of cassette coils is covered with a thermosetting resin by molding to produce the state.

Claims

1. A motor stator including a plurality of stator coils each of which is formed of a conductive coil wound on a stator core, wherein

one of the stator core and the conductive coil is integrally formed with an insulator made of a thermosetting resin by insert molding, and

the stator including the plurality of stator coils is covered with a thermosetting resin by molding.

2. The motor stator according to claim 1, wherein

the thermosetting resin forming the insulator and the thermosetting resin covering the stator including the plurality of stator coils by the molding are equal in linear expansion coefficient.

3. The motor stator according to claim 2, wherein

the resins equal in linear expansion coefficient are an epoxy thermosetting resin containing 60 to 80 vol % of filler, and

the linear expansion coefficient is 10 to 20 ppm/°

C.

4. The motor stator according to claim 1, wherein

the thermosetting resin forming the insulator is larger in heat conductivity than the thermosetting resin covering the stator by the molding.

5. The motor stator according to claim 1, wherein

the conductive coil is a coil which has a flat shape in section and is wound edgewise, and

the insulator is partly formed at four corners of one of the stator core and the conductive coil.

6. A motor stator manufacturing method for manufacturing a motor stator including a plurality of coils each of which is formed of a conductive coil wound on a stator core, comprising the steps of:

forming an insulator of a thermosetting resin in such a manner as to be integral with one of the stator core and the conductive coil by insert molding; and

covering the stator including the plurality of coils with a thermosetting resin by molding.