A manufacturing method of a stator is a method for manufacturing the stator using molds. The stator is constructed so that a stator main body and resin molded portion are integrated. The stator main body includes a terminal portion and a core. The manufacturing method includes: arranging the stator main body such that the terminal portion is located on a top portion of the molds; and filling a cavity with resin. The terminal portion has a gas discharging port configured to discharge gas out of the cavity from inside the cavity in the molds.

A manufacturing method of a stator is a method for manufacturing the stator using molds. The stator is constructed so that a stator main body and resin molded portion are integrated. The stator main body includes a terminal portion and a core. The manufacturing method includes: arranging the stator main body such that the terminal portion is located on a top portion of the molds; and filling a cavity with resin. The terminal portion has a gas discharging port configured to discharge gas out of the cavity from inside the cavity in the molds.

The present invention provides an unsaturated polyester resin composition for producing a molding resin for use in a switched reluctance motor. The unsaturated polyester resin composition comprises an unsaturated polyester, a crosslinking agent, a curing agent, a low profile additive, a filler, and a reinforcing fibrous material. The content of the filler is from 100 parts by mass to 800 parts by mass with respect to 140 parts by mass of the total of the unsaturated polyester and the crosslinking agent. The filler comprises one or more fillers (filler A) selected from the group consisting of calcium carbonate, glass, silica, talc, clay, barium sulfate, calcium silicate, titanium oxide, and a hollow filler and one or more fillers (filler B) selected from the group consisting of aluminum hydroxide and alumina. The mass ratio of filler B to filler A is 1 or more. The unsaturated polyester resin composition of the present invention is optimal for producing a molding resin for use in a switched reluctance motor, the molding resin barely causing void formation upon sealing, effectively preventing vibration of stator salient poles, and barely generating cracks when vibration and heat are generated during motor operation.

The present invention provides an unsaturated polyester resin composition for producing a molding resin for use in a switched reluctance motor. The unsaturated polyester resin composition comprises an unsaturated polyester, a crosslinking agent, a curing agent, a low profile additive, a filler, and a reinforcing fibrous material. The content of the filler is from 100 parts by mass to 800 parts by mass with respect to 140 parts by mass of the total of the unsaturated polyester and the crosslinking agent. The filler comprises one or more fillers (filler A) selected from the group consisting of calcium carbonate, glass, silica, talc, clay, barium sulfate, calcium silicate, titanium oxide, and a hollow filler and one or more fillers (filler B) selected from the group consisting of aluminum hydroxide and alumina. The mass ratio of filler B to filler A is 1 or more. The unsaturated polyester resin composition of the present invention is optimal for producing a molding resin for use in a switched reluctance motor, the molding resin barely causing void formation upon sealing, effectively preventing vibration of stator salient poles, and barely generating cracks when vibration and heat are generated during motor operation.

An adhesively-laminated core for a stator capable of suppressing an iron loss of an electric motor and also having excellent productivity is provided. The adhesively-laminated core for a stator includes a plurality of electrical steel sheets which are stacked on one another and of which both surfaces are coated with insulation coatings, and adhesion parts which are disposed between the electrical steel sheets adjacent to each other in a stacking direction and cause the electrical steel sheets to be adhered to each other. All sets of the electrical steel sheets adjacent to each other in the stacking direction are adhered via the adhesion parts. An adhesive forming the adhesion parts is a two-agent type acrylic-based adhesive (SGA) which includes an acrylic-based compound, an oxidizer, and a reducer and in which a portion of the acrylic-based compound and the oxidizer are assigned to a first agent and the remaining portion of the acrylic-based compound and the reducer are assigned to a second agent. The adhesion parts are partially provided between the electrical steel sheets adjacent to each other in the stacking direction.

A method of manufacturing a stacked stator core comprises forming a stack that comprises an annular yoke portion, a plurality of tooth portions, and a plurality of slots. The method further comprises inserting a mold core member of the plurality of mold core members into a slot of the plurality of slots, the mold core member comprising a body portion and a closing portion connected to the body portion, the body portion extending along a longitudinal direction of the slot and spaced apart from an inner wall surface of the slot, the closing portion being positioned on a slot opening side of the slot and closing an open end portion of the slot on the slot opening side. Additionally, the method comprises forming a resin portion by charging a melted resin into a filling space between the slot and the mold core member.

A method of manufacturing a stacked stator core comprises forming a stack that comprises an annular yoke portion, a plurality of tooth portions, and a plurality of slots. The method further comprises inserting a mold core member of the plurality of mold core members into a slot of the plurality of slots, the mold core member comprising a body portion and a closing portion connected to the body portion, the body portion extending along a longitudinal direction of the slot and spaced apart from an inner wall surface of the slot, the closing portion being positioned on a slot opening side of the slot and closing an open end portion of the slot on the slot opening side. Additionally, the method comprises forming a resin portion by charging a melted resin into a filling space between the slot and the mold core member.

A lamination for use in an electric machine stator includes a body having a generally circular outer periphery and a generally circular inner periphery, spaced from the outer periphery and a plurality of spaced apart teeth extending inwardly from the circular inner periphery. Each of said teeth define opposed inner edges thereof. The lamination includes a first pair of tips extending tangentially in opposed directions from the inner edge of one of said teeth and a second pair of tips extending tangentially in opposed directions from the inner edges of another one of said teeth. A tip of the first pair of tips and a tip of the second pair of tips define a first configuration having a first gap therebetween and defining a second configuration having a second gap therebetween. The first gap being substantially less than the second gap.

A lamination for use in an electric machine stator includes a body having a generally circular outer periphery and a generally circular inner periphery, spaced from the outer periphery and a plurality of spaced apart teeth extending inwardly from the circular inner periphery. Each of said teeth define opposed inner edges thereof. The lamination includes a first pair of tips extending tangentially in opposed directions from the inner edge of one of said teeth and a second pair of tips extending tangentially in opposed directions from the inner edges of another one of said teeth. A tip of the first pair of tips and a tip of the second pair of tips define a first configuration having a first gap therebetween and defining a second configuration having a second gap therebetween. The first gap being substantially less than the second gap.

Provided is an electric motor which includes an adhesively-laminated core for a stator having excellent productivity and high mechanical strength and that is thus capable of reducing vibration and noise of an electric motor and suppressing iron loss. The adhesively-laminated core for a stator includes electrical steel sheets laminated on each other and each coated on both sides with an insulation coating, and an adhesion part disposed between the electrical steel sheets adjacent to each other in a stacking direction and configured to cause the electrical steel sheets to be adhered to each other. All sets of the electrical steel sheets adjacent to each other in the stacking direction are adhered by the adhesion part, an adhesive forming the adhesion part includes a fast-curing type adhesive and a thermosetting adhesive, and the adhesion part is partially provided between the electrical steel sheets adjacent to each other in the stacking direction.