STATOR AND STATOR MANUFACTURING METHOD

• US 20160380521A1
• Filed: 12/22/2014
• Published: 12/29/2016
• Est. Priority Date: 12/26/2013
• Status: Active Grant

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: TSUCHIYA, Yukio, HATTORI, Hiroyuki
• Granted Patent: US 10,461,613 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: H02K 1/04 characterised by the material used for insulating the magnetic circuit or parts thereof
• CPC Class Codes: H02K 1/165 Shape, form or location of the slots
• CPC Class Codes: H02K 15/085 by laying conductors into slotted stators
• CPC Class Codes: H02K 15/10 Applying solid insulation to windings, stators or rotors
• CPC Class Codes: H02K 15/12 Impregnating, heating or drying of windings, stators, rotors or machines
• CPC Class Codes: H02K 3/325 for windings on salient poles, such as claw-shaped poles
• CPC Class Codes: H02K 3/345 between conductor and core, e.g. slot insulation
• CPC Class Codes: H02K 3/522 for generally annular cores with salient poles

Abstract

A stator includes a stator core and an insulator. The insulator includes a main body and a wall. An adhesive is attached to a portion of a triangular gap between the wall of the insulator and a yoke of the stator core. The adhesive is expandable, and adheres and fixes the insulator to the stator core by expanding to fill in the gap by being heated. Also, a stator manufacturing method includes attaching an adhesive to the wall of the insulator or an inside wall of the yoke, installing the insulator on a tooth, and heating the stator core and the insulator.

Claims

1. A stator comprising:

a stator core including;

a yoke that extends in a circumferential direction; and

teeth that protrude from the yoke in a radial direction, a slot being defined between the teeth which are adjacent to each other;

an insulator that is assembled to each tooth from a tip end of the tooth,

the insulator including;

a main body within which the tooth is housed; and

a wall that protrudes in a direction orthogonal to the radial direction from an end portion of the main body, a circumferentially end portion of the wall being configured to abut against an inside surface of the yoke in the slot;

a coil that is wound around the main body of the insulator; and

an adhesive that is attached only to a portion of a triangular gap between the yoke and the wall of the insulator, the adhesive being expandable, the adhesive being configured to adhere and fix the insulator to the stator core by expanding to fill in the triangular gap by being heated.

2. The stator according to claim 1, wherein

the adhesive is a sheet adhesive that is attached to the wall of the insulator or an inside surface of the yoke that corresponds to the triangular gap, before the insulator is assembled.

3. The stator according to claim 1, wherein

a radial width of the yoke that corresponds to a base end side of the tooth is larger than a radial width of the yoke that corresponds to a circumferentially center region of the slot.

4. The stator according to claim 1, wherein

the adhesive is a foaming adhesive that foams and expands by being heated.

5. The stator according to claim 1, wherein

the inside surface is a surface of the yoke that faces a radially inner side at the slot, and

the wall is arranged on an end on a radially outer side of the main body.

6. A manufacturing method for a stator, the stator including a stator core and an insulator, the stator core including a yoke that extends in a circumferential direction and teeth that protrude from the yoke in a radial direction, a slot being defined between the teeth which are adjacent to each other, the insulator including a wall and a main body around which a coil is wound, the wall protruding in a direction substantially orthogonal to the radial direction from an end portion of the main body, the manufacturing method comprising:

preparing the stator core and the insulator;

attaching an adhesive only to the wall of the insulator or only an inside surface of the yoke;

installing the insulator on the tooth so as to form a triangular gap between the wall and the yoke, by abutting a circumferentially end portion of the wall of the insulator against the inside surface of the yoke in the slot; and

heating the stator core and the insulator in order to adhere and fix the insulator to the stator core by expanding the adhesive to fill in the triangular gap.