JP2010252407A - Slotless structure of motor, electric blower, and vacuum cleaner - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a reliable slotless structure of motors having high space factors of coils. <P>SOLUTION: The slotless structure includes: a plurality of concentrated winding coils 4; an insulating and cylindrical coil bobbin 2 made of a non-magnetic material; projections 3 formed to project in a radial direction on the periphery of the coil bobbin 2, wherein the number of the projections is equal to that of the coils 4 and the coils 4 are fitted to the projections; a cylindrical stator core 1 that is disposed outside the coils 4 and includes no slots; an insulator 6 between coils disposed between the adjacent coils 4; and an insulating layer 5 for covering an area at least near an inner diameter side of the stator core 1. In this case, the coil bobbin 2 to which the coil 4 is fitted is inserted inside the insulating layer 5 for arrangement, thus reliably achieving insulation between the coils 4 and insulation between the coils 4 and the stator core 1, improving reliability and the space factor of the coils 4, thereby miniaturizing the motor and increasing its efficiency. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a slotless structure of a motor for high-speed rotation, an electric blower, and a vacuum cleaner.

  As a conventional slotless structure of a motor, there is one as shown in FIG. 5 (see, for example, Patent Document 1).

FIG. 5 is a plan view and a front view of a conventional coil bobbin having a slotless structure for a motor described in Patent Document 1. In FIG. 5, a coil bobbin 29 having a slotless structure of a conventional motor is formed in a cylindrical shape, and a plurality of protrusions 30 protruding radially from the outer periphery thereof are arranged at equal angles in the circumferential direction. In addition, an air core coil (not shown) formed in advance by self-bonding wire with concentrated winding is arranged on the protrusion 30 of the coil bobbin 29. The coil bobbin 29 is inserted into a cylindrical stator core (not shown) having an inner diameter larger than the coil bobbin 29.
JP 2002-262502 A

  However, in the slotless structure of the conventional motor described in Patent Document 1, when the space factor of the coil is increased, the insulation between the phases and the insulation between the coil and the stator core are not ensured by the insulating member. It had the subject that reliability fell.

  SUMMARY OF THE INVENTION The present invention solves the above-described conventional problems, and an object thereof is to provide a slotless structure of a motor that can ensure interphase insulation and insulation between a coil and a stator core with an insulating member.

  In order to solve the above-described conventional problems, the slotless structure of the motor according to the present invention includes a plurality of concentrated winding coils, a cylindrical coil bobbin made of insulating and non-magnetic material, and a radial direction on the outer periphery of the coil bobbin. And a projection portion on which the coils are mounted in the same number as each of the coils, a cylindrical stator core that is disposed outside the coils and has no slots, and is disposed between the adjacent coils. An insulator between coils and a stator insulator covering at least the inner diameter side of the stator core are provided, and the coil bobbin on which the coil is mounted is inserted and arranged inside the stator insulator. Insulation performance such as interphase insulation can be improved, and by forming a sufficient insulating layer on the stator core in advance, Insulation between stator core can be reliably performed. Thereby, it is possible to reduce the size and increase the efficiency of the motor by improving the reliability and the coil space factor.

  An electric blower according to the present invention includes a motor using the slotless structure of the motor according to any one of claims 1 to 13 and a fan. Efficiency can be improved.

  Moreover, the electric vacuum cleaner of the present invention is provided with the electric blower according to claim 14, and is improved in reliability, downsized and highly efficient, and has a high suction performance and can be cleaned comfortably. It is.

  The slotless structure of the motor, the electric blower, and the vacuum cleaner of the present invention can be miniaturized while having high efficiency.

  According to a first aspect of the present invention, a plurality of concentrated winding coils, a cylindrical coil bobbin made of an insulating and non-magnetic material, and projecting radially on the outer periphery of the coil bobbin are provided in the same number as the coils. A projection portion to which the coil is mounted, a cylindrical stator core that is disposed outside the coil and has no slots, an inter-coil insulator disposed between the adjacent coils, and at least the vicinity of the inner diameter side of the stator core The coil bobbin on which the coil is mounted is inserted and arranged inside the stator insulator, and the insulation between the coils can be ensured, so that the insulation performance such as interphase insulation is improved. By forming a sufficient insulating layer on the stator core in advance, the coil and the stator core can be reliably insulated. Thereby, it is possible to reduce the size and increase the efficiency of the motor by improving the reliability and the coil space factor.

  In the second invention, in particular, the inner diameter portion of the stator insulator of the first invention protrudes in a cylindrical shape from the end face of the stator core in the stacking direction of the stator core. When the coil end is formed after the coil is inserted into the stator core so as to be bent to the side, stress concentration on the inner diameter side edge of the stator core is alleviated and the insulating layer is not easily damaged. Therefore, since the insulating layer can be suppressed to the minimum necessary thickness, it is possible to reduce the size and increase the efficiency by improving the space factor.

  In the third invention, in particular, the stator insulator of the first or second invention is made of resin by integral molding, and since it can be formed with good adhesion to the stator core seamlessly, the coil and stator core The reliability of the insulation between them can be increased. In addition, since reliable insulation can be ensured, it is possible to reduce the size and increase the efficiency by improving the space factor.

  In the fourth invention, in particular, the stator insulator of the first or second invention is formed by deforming a film by mechanical ductility processing or thermal deformation, and a pinholeless thin insulating layer is formed. It becomes possible. As a result, it becomes easier to secure more space for accommodating the coils, and therefore it becomes possible to reduce the size and increase the efficiency by improving the space factor.

  In the fifth invention, in particular, the stator insulator according to the first or second invention is composed of at least two members formed by cutting, folding and bending, and is configured by a combination of simple processing. Since the restrictions due to processing such as dimensions and materials are very small, it is possible to aim for downsizing and high efficiency by improving the space factor at low cost.

  In the sixth invention, in particular, the inter-coil insulator according to any one of the first to fifth inventions is made of a flexible plate or film. When the coil is inserted into the coil bobbin, or the coil and the coil bobbin are used as the stator core. Since it can be prevented from being damaged by stress on the inter-coil insulator that occurs along with the shaping of the coil at the time of insertion, a higher space factor can be aimed at, and miniaturization and higher efficiency can be achieved. .

In the seventh invention, in particular, the inter-coil insulator of any one of the first to fifth inventions is made of an insulating tape having an insulating film and an adhesive layer, and fits at least within the inner diameter of the stator core at the straight portion of the coil. Covers the part or the part that comes into contact with the adjacent coil, and it is high because the insulation film can be made as thin as necessary without wire breakage or spillage, and reliable insulation can be secured without breakage. It is possible to obtain reliability and to reduce the size and increase the efficiency by improving the space factor.

  In the eighth invention, in particular, the inter-coil insulator according to any one of the first to fifth inventions has an arcuate surface along a cylindrical outer periphery on the inner diameter side and a straight portion that fits on the inner diameter side of the stator core of the coil. It has a shape that sandwiches at least one side, is easy to handle without deterioration of the adhesive layer such as tape, and has the effect of shaping it into a shape close to the final shape with a single coil, high reliability and certainty Since insulation can be ensured, it is possible to reduce the size and increase the efficiency by improving the space factor.

  In the ninth aspect of the invention, in particular, the protrusion of any one of the first to eighth aspects is arranged so as to fit into a groove provided in the inner diameter of the stator core. It is possible to prevent a gap between the coils from being shifted due to a stress caused by a mold or the like and to prevent a phase shift of the coils. Further, the position of the coil with respect to the stator core can be determined, and the position with respect to the assembly of the motor and sensor can be easily adjusted.

  In the tenth aspect of the invention, in particular, the tip of the protrusion of the ninth aspect of the invention is narrowed, and it is easy to fit into the stator core, and is more tapered than the final coil position when the coil is inserted into the coil bobbin. Since it protrudes, it is easy to prevent line spillage, so that high reliability can be obtained.

  In the eleventh aspect of the invention, in particular, the outer peripheral surface of the stator core according to any one of the first to tenth aspects of the invention is extended in the product pressure direction of the stator core at a position extending radially from the center position of each coil. In the case of a cylindrical stator core, the position in the circumferential direction is determined while minimizing the influence on the magnetic flux passing through the stator core, and a bracket is arranged so as to sandwich the stator core so By using this hollow shape when passing the tape, it is easy to assemble and can be reduced in size and efficiency.

  In the twelfth invention, the coil and the stator core according to any one of the first to eleventh inventions are molded with resin, and the noise from the coil due to electromagnetic vibration during motor driving is suppressed and particularly for cooling. When it is difficult to apply the wind to the coil, heat from the coil can be efficiently transmitted, which is advantageous for heat dissipation. In addition, since the coil end is covered with the resin and is hardly damaged and can be reliably insulated, the reliability can be improved. In addition, since reliable insulation can be ensured, it is possible to reduce the size and increase the efficiency by improving the space factor.

  In a thirteenth aspect of the invention, in particular, after the coil bobbin according to any one of the first to twelfth aspects of the invention is assembled to a stator core, the inner diameter of the coil bobbin is scraped to such an extent that no coil appears. If the inner diameter of the coil bobbin is deformed due to the degree of fitting or the force that the coil pushes back, the cylindricity of the inner diameter can be improved to ensure the distance from the rotor and the smooth shape. Since it becomes a state advantageous to a windage loss, high efficiency and miniaturization of the motor can be achieved.

  An electric blower according to a fourteenth aspect of the present invention comprises a motor using the motor slotless structure according to any one of claims 1 to 13 and a fan. Efficiency can be improved.

  A vacuum cleaner according to a fifteenth aspect of the present invention includes the electric blower according to claim 14, which is improved in reliability, reduced in size and increased in efficiency, has high suction performance, and can be cleaned comfortably. It is.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. Note that the present invention is not limited to the embodiments.

(Embodiment 1)
1 is a cross-sectional view of a coil bobbin, a coil, and a stator core having a slotless structure for a motor according to Embodiment 1 of the present invention. FIG. 2 is a cross-sectional view of the stator core, an inner diameter thereof, and an insulating layer at an end face. FIG. 3 is an external view of a slotless coil and an insulating tape of the motor.

  As shown in FIG. 1, the slotless structure of the motor according to the present embodiment includes a cylindrical stator core 1, a coil bobbin 2 that is disposed inside the stator core 1, has an insulating property, and is made of a nonmagnetic material, and a coil bobbin 2. It is composed of a plurality of concentrated winding coils 4 mounted on a cylindrical outer periphery.

  On the outer periphery of the cylindrical shape of the coil bobbin 2, the same number of the coils 4 as the number of the coils 4, and projections 3 on which the coils 4 are mounted are formed so as to protrude in the radial direction and extend in the axial direction. Further, the concentrated winding coil 4 is inserted into the protrusion 3 and assembled so as to fit inside the insulating layer 5 as a stator insulator covering the inner diameter of the stator core 1 so that the stator core 1 and the coil 4 are insulated. .

  Further, a flexible inter-coil insulator 6 is disposed between the adjacent coils 4. The inter-coil insulator 6 is assembled with the coil bobbin 2 by integral molding, welding, adhesion, fitting, or the like. The outer periphery of the stator core 1 has a concave shape 7 on the center position of each coil, that is, on the radial extension line of the protrusion 3 of the coil bobbin 2. Thus, the influence on the magnetic flux 8 flowing inside the stator core 1 can be reduced and used for circumferential positioning, assembly bolting, and the like.

  Further, the tip of the protrusion 3 is thin. For example, when the groove 9 (not shown) on the inner diameter side of the stator core 1 is formed along the protrusion 9 at the tip of the triangular shape, the protrusion The positioning accuracy of 3 can be increased. Further, when the protrusion 3 is formed as a trapezoidal tip protrusion 10 and the groove on the inner diameter side of the stator core 1 is along this, it is possible to facilitate fitting while maintaining positioning accuracy. Further, the same effect can be obtained even if the tip is a projection 11 with an arcuate tip, and it is easy to suppress chipping of the tip edge portion and dust generated when the projection 3 and the stator core 1 are fitted. Can do.

  Next, the stator core 1 and the inner diameter side insulating layer 5 will be described with reference to FIG.

  In FIG. 2, as a method of forming the stator core 1 and the insulating layer 5 of the inner diameter and end face thereof, when the inner diameter and end face of the stator core 1 are formed by integral molding, a film-like insulator is mechanically ductile processed or There are cases (b) in which it is formed by heat shaping and cases (c) in which it is formed by an insulating member processed by two or more cutting and folding / bending.

  First, when the insulating layer 5 is formed by integral molding (a), the insulating layer 5 is formed so as to cover one surface from the inner diameter to the end surface of the stator core 1 in consideration of the retaining effect.

When a coil end (not shown) is bent or crushed after being inserted into the stator core 1, stress tends to concentrate on the edge portion of the insulating layer 5, so that it protrudes in a cylindrical shape in the stacking direction of the stator core 1. The stress concentration can be alleviated, and damage at the edge portion of the insulating layer 5 can be prevented. Further, if the protruding portion of the insulating layer 5 is tapered or arcuate, the coil 4 can be prevented from being damaged. At this time, if a sufficient area of the end face side is covered with the insulating layer 5, contact between the stator core 1 and the coil 4 can be prevented by wire spillage or wire dripping at the coil end, and the insulation reliability can be improved.

  When the insulating layer 5 is formed by mechanical ductility processing or heat shaping of a film-like insulator (b), the inner diameter of the stator core 1 is shaped by shaping the film-like insulator 5a and the inner edge of the stator core 1 is formed. Cover at least one from the end to the end face. In the case of performing the coil shaping to suppress the height of the coil end of the coil 4 on the end face opposite to the end face covered with this, in order to prevent a problem of insulation quality due to line spillage depending on the degree of shaping, the stator core 1 An insulating layer 5b is provided to cover the end face. If the side that does not cover the end face of the film-like insulator 5a is tapered, it is useful for preventing damage to the film-like insulator 5a and the coil 4 when coil shaping is performed. Compared to the case of integral molding, it is possible to prepare for production at low cost because no large-scale equipment is required.

  Further, when the insulating layer 5 is formed of two or more insulating members processed by cutting and folding / bending (c), the insulating layer 5 is formed by cutting out or bending a film-like or plate-like insulator. When there is a concern about contact between the coil 4 and the stator core 1 due to wire spillage at the coil end, the insulating layers 5c and 5d are provided on the end face side. The inner diameter side insulating layer 5e provided on the inner diameter of the stator core 1 can be bent to the outer peripheral side to prevent it from coming off and prevent the coil 4 from being damaged at the edge of the inner diameter side insulating layer 5e. In this method, since the insulating member is simply cut out or bent, production preparation can be performed at a very low cost.

  Next, the case where the inter-coil insulator 6 is formed of an insulating tape will be described with reference to FIG.

  FIG. 3A shows an insulating, flexible, and adhesive layer as an inter-coil insulator 6 on the outside of the side that can be in contact with the adjacent coil 4 within the inner diameter of the stator core 1 of the concentrated coil 4. The example which affixed the insulating tape 20 is shown. As a result, it is possible to prevent excessive variation in the wire of the coil 4 and to form a very thin insulating layer without a pinhole. Further, as shown in FIG. 3B, by sticking one or more turns of the insulating tape 20, it is difficult to cause deviation or peeling, and the two coils 4 can be reliably insulated. As described above, by using an insulating tape, it is possible to achieve thin insulation between coils, and the space factor can be improved accordingly.

  Note that the coil bobbin 2 and the assembled inter-coil insulator 6 and an insulating tape attached to the side of the coil 4 may be used in combination.

  In addition, although the front-end | tip of the projection part 3 was made into triangle shape, trapezoid shape, or circular arc shape, the effect of this invention will be acquired if the front-end | tip is thin even if it is what kind of shape.

  Although the film-like insulator 5a covers the end face of one stator core 1, it may be processed so as to cover the other end face so as to have the function of the insulating layer 5b.

(Embodiment 2)
FIG. 4 is a cross-sectional view of a coil bobbin having a slotless structure for a motor according to a second embodiment of the present invention, insulation between coils in a shape sandwiching a coil and a single coil piece. In addition, the same code | symbol is attached | subjected to the same part as the slotless structure of the motor in the said 1st Embodiment, and the description is abbreviate | omitted.

In the present embodiment, as shown in FIG. 4, similarly to the first embodiment, the protrusion 3 is provided on the outer peripheral surface of the coil bobbin 2, and the concentrated coil 4 is inserted therein. The outer peripheral side of the coil 4 is covered with an insulating layer 25 formed on the inner diameter of the stator coil 28. In the coil 4, an inter-coil insulator 26 having a “U” -shaped cross section disposed so as to sandwich the coil piece between pieces facing each other adjacent coils 4 is arranged. As a result, it is possible to easily assemble without the step of sticking, and it is possible to increase the creepage distance between the coils 4.

  Further, as shown in the same figure, as the insulation between the adjacent coils 4, the inter-coil insulator 27 having a substantially “U” cross section is used to prevent the two sides of the coil 4 from being scattered. It becomes possible. As a result, it is possible to prevent deterioration in insulation quality due to wire spillage.

  Further, by integrally forming the coil bobbin 2, the coil 4 and the stator core 28 including the coil end, noise from the coil 4 due to electromagnetic vibration during driving of the motor is suppressed, and in particular, the wind for cooling is coiled. When it is difficult to apply the power to the coil 4, the heat from the coil 4 can be efficiently transmitted, which is advantageous for heat radiation. In addition, since the coil end is covered with the resin and is hardly damaged and can be reliably insulated, the reliability can be improved. In addition, since reliable insulation can be ensured, it is possible to reduce the size and increase the efficiency by improving the space factor.

  In the present embodiment, it has been described that the coil bobbin 2 and the coil 4 are integrally molded. However, the same effect can be obtained even if the coil bobbin 2 and the coil 4 are used in the first embodiment.

  Note that, after the coil bobbin 2 is assembled to the stator core 1, the distance between the coil 4 and the rotor (not shown) is substantially shortened by scraping the inner diameter of the coil bobbin 2 to such an extent that the coil 4 does not appear. If the inner diameter of the coil bobbin 2 is deformed by the degree of fitting or the force that the coil 4 pushes back, the cylindricity of the inner diameter is improved, the distance from the rotor is ensured, and the smooth shape is advantageous for windage loss. Therefore, the motor can be made highly efficient and downsized.

  By adopting the slotless structure described in the above embodiment for the motor, the motor can be made highly efficient and downsized. Therefore, the efficiency and downsizing of the electric blower comprising the motor and the fan can be reduced. It goes without saying that it can be achieved. In particular, when a slotless structure is employed, since the iron loss is small, high efficiency can be achieved even at high speed rotation, so that further reduction in size can be achieved by reducing the diameter of the fan accompanying high speed rotation.

  If the motor is highly efficient and downsized according to the above embodiment, the efficiency and size of the electric blower having the slotless structure of the motor can be improved. Since it can also be applied to household electrical appliances and industrial equipment, it is possible to achieve high efficiency and miniaturization, which are similar effects.

  In addition, since the said electric blower acts also as a generator by giving rotational drive energy from the outside, it becomes possible to aim at the same high efficiency and size reduction as the above. For example, in a micro gas turbine or the like, it can be applied to an application that acts as an electric motor as a starter at start-up and acts as a generator when the gas turbine operates. Needless to say, the power generation operation at high speed can be applied to a detector such as a speed sensor using an induced voltage / current signal.

  As described above, the slotless structure of the motor according to the present invention can reliably insulate between the coil and the stator or between the coils. Efficiency can be improved.

  Also, an electric blower having a motor using this slotless structure can be downsized while having high efficiency. Therefore, it can be widely applied not only as a vacuum cleaner and a generator, but also in other household appliances, industrial equipment and the like. For example, it operates as a starter at start-up in a micro gas turbine and switches to a generator when the turbine works. Furthermore, the electric blower can be applied to a compressor, a turbine, and a liquid pump from the same viewpoint. Needless to say, the function as a generator for high-speed rotation can be applied to a detector such as a speed sensor using an induced voltage.

Sectional drawing of the coil bobbin, coil, and stator core of the slotless structure of the motor in Embodiment 1 of this invention (A) Cross-sectional view of the stator core, inner diameter and end face insulating layer (b) Cross-sectional view showing another example of the slotless structure of the motor (c) Cross-sectional view showing another example of the slotless structure of the motor (A) External view of coil and insulating tape of slotless structure of same motor (b) External view showing another example of slotless structure of same motor Sectional drawing of insulation between coils of the shape which pinches | interposes the coil bobbin, coil, and single coil piece of the slotless structure of the motor in Embodiment 2 of this invention (A) Plan view of a coil bobbin having a slotless structure of a conventional motor (b) Front view of the coil bobbin

1, 28 Stator core 2 Coil bobbin 3 Protrusion 4 Coil 5, 25 Insulating layer (stator insulator)
6, 26, 27 Insulator between coils 7 Dimple shape 8 Magnetic flux 9, 10, 11 Protrusion 20 Insulation tape (insulator between coils)

Claims (15)

A plurality of concentrated winding coils, a cylindrical coil bobbin made of insulating and non-magnetic material, and formed to project radially on the outer periphery of the coil bobbin, and the same number of the coils are mounted on each of the coils. A cylindrical stator core without a slot disposed outside the coil, an inter-coil insulator disposed between the adjacent coils, and a stator insulator that covers at least the vicinity of the inner diameter side of the stator core. A slotless structure for a motor, wherein the coil bobbin having the coil mounted thereon is inserted and disposed inside the stator insulator. 2. The slotless structure for a motor according to claim 1, wherein an inner diameter portion of the stator insulator protrudes in a cylindrical shape from an end face of the stator core in a thickness direction of the stator core. The slotless structure for a motor according to claim 1 or 2, wherein the stator insulator is made of resin by integral molding. The slotless structure for a motor according to claim 1 or 2, wherein the stator insulator is formed by deforming a film by mechanical ductility processing or thermal deformation. 3. The slotless structure for a motor according to claim 1, wherein the stator insulator is made of at least two members formed by cutting, folding and bending. The slotless structure for a motor according to any one of claims 1 to 5, wherein the inter-coil insulator is made of a flexible plate or film. The inter-coil insulator is made of an insulating tape having an insulating film and an adhesive layer, and covers at least a portion that fits within the inner diameter of the stator core or a portion that contacts the adjacent coil at the straight portion of the coil. The slotless structure of the motor according to any one of 1 to 5. 6. The inter-coil insulator has a shape that sandwiches at least one side of a straight portion that fits on an inner diameter side of a stator core of a coil and an arc-shaped surface along a cylindrical outer periphery on the inner diameter side. 2. A slotless structure for a motor according to claim 1. 9. The slotless structure for a motor according to claim 1, wherein the protrusion is disposed so as to be fitted in a groove provided on an inner diameter of the stator core. The slotless structure for a motor according to claim 9, wherein the tip of the protrusion is thin. 11. The stator core according to claim 1, further comprising a hollow shape extending in a product pressure direction of the stator core at a position extending radially from the center position of each coil on the outer peripheral surface of the stator core. 2. A slotless structure for a motor according to item 1. The slotless structure for a motor according to any one of claims 1 to 11, wherein the coil and the stator core are formed of resin. The slotless structure for a motor according to any one of claims 1 to 12, wherein after the coil bobbin is assembled to the stator core, the inner diameter of the coil bobbin is scraped off to such an extent that no coil appears. The electric blower comprised with the motor using the slotless structure of the motor of any one of Claims 1-13, and the fan. The vacuum cleaner provided with the electric blower of Claim 14.