Stator having an insulating film for a coil

Abstract

A stator includes a stator core, and a coil mounted on the stator core and having an insulating film, at least a part of the insulating film being coated with a protective paint, wherein the insulating film has a vacancy, and the vacancy is formed by a hollow capsule. In addition, the protective paint has a powder, and an internal form of the vacancy is smaller than an external form of the powder.

Claims

1. A stator comprising: a stator core; and a coil mounted on the stator core and having an insulating film, at least a part of the insulating film being coated with a protective paint, wherein the insulating film has vacancies therein, the vacancies are formed by hollow capsules, the protective paint has a powder, an internal form of the vacancies is smaller than an external form of the powder, and at least a portion of the capsules are exposed at a surface of the insulating film.

2. The stator according to claim 1, wherein at least a part of at least one capsule is exposed at an outer circumferential surface of the insulating film.

3. A method of manufacturing a stator, comprising: a coil mounting process of mounting a coil on a stator core, the coil having a conductor and an insulating film configured to cover the conductor and having a vacancy formed by a hollow capsule therein; and a coating process of applying a protective paint on the conductor and the insulating film of a coil end protruding from the stator core due to the coil mounting process to perform insulation processing on the coil end, wherein the protective paint has a powder, and an internal form of the vacancy is smaller than an external form of the powder.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of a stator according to a first embodiment.

(2) FIG. 2 is an enlarged view of a coil end according to the first embodiment.

(3) FIG. 3 is a cross-sectional view of a coil in the vicinity of a welding section according to the first embodiment.

(4) FIG. 4 is a cross-sectional view of a portion IV in FIG. 3.

(5) FIG. 5 is a cross-sectional view of a portion IV in FIG. 3 in the related art.

DETAILED DESCRIPTION OF THE INVENTION

(6) Hereinafter, an embodiment of the present invention will be described with reference to the accompanying drawings.

(7) FIG. 1 is a perspective view of appearance of a stator 1. The stator 1 includes a stator core 3 and a coil 4.

(8) The stator core 3 is formed in an annular shape about an axis C. Teeth 7 are formed on an inner circumferential surface of the stator core 3. The teeth 7 protrude inward from the inner circumferential surface of the stator core 3 in the radial direction. A plurality of teeth 7 are provided in a circumferential direction. Slots 8 are formed between the teeth 7, and the coil 4, which will be described below, is inserted into the slots 8. A rotor (not shown) is pivotably disposed about the axis C in the stator core 3.

(9) In the following description, a direction along the axis C of the stator core 3 may be referred to as an axial direction, a direction perpendicular to the axis C may be referred to as a radial direction, and a direction around the axis C may be referred to as a circumferential direction.

(10) The coil 4 is mounted in the slots 8 of the stator core 3. Specifically, the coil 4 is fixed to the stator core 3 by inserting the coil 4 into the slots 8 from one side in the axial direction (a lower side in FIG. 1) while overlapping plural times in the radial direction and the circumferential direction, and joining tip portions of the coil 4 protruding from the slots 8 toward the other side in the axial direction (an upper side in FIG. 1). A portion of the coil 4 inserted into the slots 8 is a coil insertion section 41, and portions protruding from an end surface of the stator core 3 toward one side and the other side in the axial direction are coil ends 42.

(11) The coil 4 has a conductor 10, an insulating film 20 and a protective paint 30 (see FIG. 2).

(12) FIG. 2 is an enlarged view of the coil ends 42 protruding toward the other side in the axial direction.

(13) The conductor 10 configures a core portion of the coil 4, and is formed in a linear shape having a rectangular cross section. The conductor 10 has welding sections 11 formed on tip portions of the coil ends 42 protruding toward the other side in the axial direction. The neighboring welding sections 11 are electrically and physically bonded to each other through welding.

(14) FIG. 3 is a cross-sectional view of the coil 4 in the vicinity of the welding sections 11, and FIG. 4 is a cross-sectional view of a portion IV in FIG. 3.

(15) The insulating film 20 covers an outer circumferential section of the conductor 10. The insulating film 20 is formed of an insulating material such as a resin or the like. The insulating film 20 is formed throughout the length of the conductor 10 except in the vicinity of the welding sections 11. In other words, the conductor 10 is exposed with respect to the insulating film 20 in the vicinity of the welding sections 11. A portion of the conductor 10 exposed from the insulating film 20 and at least a part of the insulating film 20 are coated with the protective paint 30.

(16) The insulating film 20 has a film main body 21, a capsule 23 (see FIG. 4), convex sections 24 and concave sections 25.

(17) The film main body 21 is formed of an insulating resin such as polyimide or the like.

(18) As shown in FIG. 4, the film main body 21 has a plurality of hollow capsules 23 formed therein.

(19) The capsules 23 are formed of a resin different from that of the film main body 21. The capsules 23 are formed of a resin such as a silicone or the like. The capsule 23 is formed in a spherical shape. The inside of the capsule 23 is a vacancy 22.

(20) Among the capsules 23, portions at least some parts are exposed to the outside compared to an outer circumferential surface of the film main body 21 are referred as the convex sections 24. Portions between the convex sections 24 are referred as the concave sections 25. That is, the concave sections 25 are formed in a surface of the insulating film 20 by the capsules 23.

(21) The conductor 10 exposed from the insulating film 20 and the insulating film 20 in the vicinity thereof are coated with the protective paint 30. The protective paint 30 enters the concave section 25. The protective paint 30 has a powder 31. Specifically, the coating by the protective paint 30 is so-called powder coating of attaching the powder 31 to a member to be painted (in the embodiment, the conductor 10 and the insulating film 20) and then heating the powder to form a protective film. An external form of the powder 31 is smaller than an internal form of the concave section 25, and larger than an external form of the capsule 23. In the embodiment, the powder 31 enters the concave section.

(22) Here, provided that a dielectric constant of the film main body 21 is α, a dielectric constant of the insulating film 20 having the vacancy 22 therein is β, a dielectric constant of air (the vacancy 22) is γ, and a dielectric constant of the protective paint 30 is ε, the relationship is ε>α>β>γ. Accordingly, when the film main body 21 includes the vacancy 22 therein, the dielectric constant β of the insulating film 20 is smaller than the dielectric constant α of the film main body 21.

(23) A process of manufacturing the stator 1 has a coil mounting process of mounting the coil 4 on the stator core 3, and a coating process of performing insulation processing on a coil end.

(24) In the coil mounting process, first, in a state in which the coil 4 formed in a U shape overlaps in the radial direction and the circumferential direction, the coil 4 is inserted into the slots 8 of the stator core 3 from one side in the axial direction. Next, the coil 4 is fixed to the stator core 3 by welding portions of the conductor 10 of the coil 4 protruding from the other side in the axial direction to each other.

(25) In the coating process, the coil ends 42 of the coil 4 protruding toward the other side in the axial direction is coated with the protective paint 30 in the coil mounting process. More specifically, first, the powder 31 is sprayed to cover the exposed conductor 10 and the insulating film 20 in the vicinity of the conductor 10. After that, coating is completed by fixing the protective paint 30 to the conductor 10 and the insulating film 20 through baking. Further, the coating process also functions as insulating processing of the coil ends 42.

(26) (Actions, Effects)

(27) Next, actions and effects of the stator 1 will be described.

(28) According to the stator 1 of the configuration, since the insulating film 20 has the vacancy 22 having a lower dielectric constant than that of a material that forms the insulating film 20 therein, the dielectric constant of the insulating film 20 is decreased by the vacancy 22. Accordingly, when used as the insulating film 20 of a coil used at a high voltage, occurrence of the partial discharge in the insulating film 20 can be minimized. Accordingly, insulation performance of the insulating film 20 can be improved.

(29) Here, when powder coating is performed on an insulating film with vacancies having no capsules 23 in the related art, as shown in FIG. 5, the protective paint 30 easily enters the concave sections 25 of the insulating film surface formed by the vacancy 22. Since the dielectric constant c of the protective paint 30 is larger than the dielectric constant β of the insulating film 20, when the protective paint 30 enters the vacancy 22, the dielectric constant β of the insulating film 20 may be increased, and the insulation performance may be decreased.

(30) According to the configuration, since the vacancy 22 is formed by the hollow capsule 23, the convex sections 24 are formed in the surface of the insulating film 20 as the plurality of capsules 23 protrude. Accordingly, when the insulating film 20 is coated with the protective paint 30, entry of the protective paint 30 into the vacancies 22 can be inhibited. Accordingly, in comparison with the case in which coating is performed on the insulating film 20 with the vacancy 22 having no capsule 23, a decrease in insulation performance due to an increase in dielectric constant of the insulating film 20, which is caused by the protective paint 30 having a high dielectric constant entering the vacancy 22, can be minimized. Accordingly, when the coating is performed on the insulating film 20 with the vacancy 22, insulation performance of the insulating film 20 can be maintained.

(31) Further, the concave sections 25 are formed between the convex sections 24 formed in the surface of the insulating film 20 due to the capsules 23, and an adhesive property of the protective paint 30 with respect to the insulating film 20 is improved by an anchor effect that the protective paint 30 enters the concave sections 25. Accordingly, peeling and raising of the protective paint 30 with respect to the insulating film 20 can be minimized, and a decrease in insulation performance due to foreign substance mixing or exposure of the conductor 10 can be minimized. Accordingly, an insulating effect due to the coating can be highly maintained.

(32) Accordingly, it is possible to provide the stator 1 in which insulation performance of the insulating film 20 is improved.

(33) In addition, since the protective paint 30 has the powder 31 and the internal form of the vacancy 22 in the insulating film 20 is smaller than the external form of the powder 31, for example, even when the capsule 23 configured to cover the vacancy 22 is broken due to an impact or the like, there is no possibility that the powder 31 enters the vacancy 22. Accordingly, the protective paint 30 having a higher dielectric constant than that of air enters the vacancy 22, and a decrease in insulation performance due to an increase in dielectric constant of the insulating film 20 can be minimized.

(34) Accordingly, it is possible to provide the stator 1 in which insulation performance of the insulating film 20 is improved.

(35) In addition, according to the method of manufacturing the stator 1 of the configuration, the stator 1 is manufactured by the coil mounting process of mounting the coil 4 on the stator core 3, and the coating process of coating the coil end 42 with the protective paint 30 to perform insulation processing. Here, since the insulating film 20 of the coil 4 has the hollow capsules 23, the dielectric constant of the insulating film 20 is decreased due to the vacancy 22. Accordingly, when used as the insulating film 20 of the coil 4 used at a high voltage, occurrence of partial discharge in the insulating film 20 can be minimized.

(36) In addition, since the convex sections 24 are formed in the surface of the insulating film 20 as the plurality of capsules 23 protrude, when the insulating film 20 is coated with the protective paint 30, entry of the protective paint 30 into the vacancies 22 can be inhibited. Accordingly, in comparison with the case in which coating is performed on the insulating film 20 with the vacancy 22 having no capsule 23, a decrease in insulation performance due to an increase in dielectric constant of the insulating film 20, which is caused by the protective paint 30 having a high dielectric constant entering the vacancy 22, can be minimized. Accordingly, when coating is performed on the insulating film 20 with the vacancy 22, insulation performance of the insulating film 20 can be maintained.

(37) Further, the concave sections 25 are formed between the convex sections 24 formed in the surface of the insulating film 20 due to the capsules 23, and the adhesive property of the protective paint 30 with respect to the insulating film 20 is improved by the anchor effect that the protective paint 30 enters the concave sections 25. Accordingly, peeling and raising of the protective paint 30 with respect to the insulating film 20 can be minimized, and a decrease in insulation performance due to foreign substance mixing or exposure of the conductor 10 can be minimized. Accordingly, an insulating effect due to the coating can be highly maintained.

(38) Accordingly, it is possible to provide the method of manufacturing the stator 1 in which insulation performance of the insulating film 20 is improved.

(39) In addition, since the protective paint 30 has the powder 31 and the internal form of the vacancy 22 in the insulating film 20 is smaller than the external form of the powder 31, for example, even when the capsule 23 configured to cover the vacancy 22 is broken due to an impact or the like, there is no possibility that the powder 31 enter the vacancy 22. Accordingly, the protective paint 30 having a higher dielectric constant than that of air enters the vacancy 22, and a decrease in insulation performance due to an increase in dielectric constant of the insulating film 20 can be minimized.

(40) Accordingly, it is possible to provide the method of manufacturing the stator 1 in which insulation performance of the insulating film 20 is improved.

(41) Further, the technical range of the present invention is not limited to the embodiment and various modifications may be made without departing from the scope of the present invention.

(42) For example, a material of the film main body 21 may be an insulating resin other than polyimide.

(43) While preferred embodiments of the invention have been described and illustrated above, it should be understood that these are exemplary of the invention and are not to be considered as limiting. Additions, omissions, substitutions, and other modifications can be made without departing from the scope of the present invention. Accordingly, the invention is not to be considered as being limited by the foregoing description, and is only limited by the scope of the appended claims.