METHOD OF MANUFACTURING STATOR, STATOR, AND MOTOR

There is provided a method of manufacturing a stator, including: an adjustment step of adjusting a thickness of a laminated body including a laminated group of soft magnetic alloy strips containing, in whole or in part, soft magnetic alloy strips obtained by heat-treating amorphous alloy strips and metal plates, the metal plates sandwiching the laminated group; a winding step of fastening the laminated body to a base and performing winding at a predetermined prat of the laminated body in a laminating direction; a removal step of releasing the fastening of the laminated body to the base and removing foreign matters from an end surface of the laminated body; and a fastening step of fastening the laminated body to the base again.

TECHNICAL FIELD

The present disclosure relates to a method of manufacturing a stator in which soft magnetic alloy strips are laminated, a stator, and a motor.

BACKGROUND ART

In the related art, pure iron or electromagnetic steel sheet is generally used for a stator of a motor. In the motor for the purpose of improving efficiency, there is a motor in which a stator core is configured of strips containing amorphous or nanocrystal grains (for example, refer to Patent Literature 1).

The stator core of Patent Literature 1 is manufactured by the following steps.

First, an amorphous alloy strip produced by a liquid quenching method such as a single roll method or a double roll method is processed into a predetermined shape by winding, cutting, punching, etching or the like.

Next, in order to improve the soft magnetic properties of the alloy strips, the amorphous alloy strips are heat-treated and crystallized. Accordingly, soft magnetic alloy strips containing nanocrystal grains are produced.

Next, a plurality of soft magnetic alloy strips are laminated to make a stator core. At this time, the stator core is bonded or molded with resin.

The stator core produced by the above steps is used for a motor.

CITATION LIST

Patent Literature

SUMMARY OF THE INVENTION

However, the motor of Patent Literature 1 has a problem that the space factor becomes small and the efficiency becomes poor because the resin or the adhesive enters between layers of the alloy strips from the side surface.

In order to increase the space factor, a laminated body of only soft magnetic alloy strips may be firmly fastened with bolts. However, there is a problem in this case. Hereinafter, this problem will be described in detail with reference toFIGS. 15A to 15C.

FIGS. 15A to 15Cillustrate the vicinity of a fastener (a part where bolt42is provided) of the laminated body of the soft magnetic alloy strips.FIG. 15Ais a sectional view of the vicinity of the fastener.FIG. 15Bis a partially enlarged sectional view of the vicinity of the fastener illustrated inFIG. 15A.FIG. 15Cis a top view of the vicinity of the fastener illustrated inFIG. 15B.

As illustrated inFIG. 15A, laminated group41of the soft magnetic alloy strips is fixed by bolt42. Bolt42is fastened to leg44of a base passing through washer43and through-hole45. After fastening bolt42, as illustrated inFIG. 15B, soft magnetic alloy strip46basically adheres tightly without a gap in a laminating direction (vertical direction in the drawing).

However, as illustrated inFIG. 15B, in a place where washer43is not restrained, soft magnetic alloy strip46has low rigidity and therefore tends to form gap48and widen. At this time, deformed part47is generated in soft magnetic alloy strip46around washer43. The swelling caused by deformed part47becomes larger toward the end of laminated group41of the soft magnetic alloy strips in the laminating direction.

Further, as illustrated inFIG. 15C, the rotational force of washer43when bolt42is fastened causes twisting of soft magnetic alloy strip46in the direction of the arrow in the drawing.

When the degree of swelling or twisting described above exceeds the limit of breakage of soft magnetic alloy strip46, a damage such as breakage occurs in soft magnetic alloy strip46. When damage occurs, a magnetic path during driving becomes discontinuous, unlike the design. As a result, the magnetic characteristics deteriorate. Furthermore, debris generated by the damage enters a rotating part, which impairs the driving of the motor.

An object of one aspect of the present disclosure is to provide a method of manufacturing a stator, a stator, and a motor that can ensure the characteristics and reliability of the motor.

According to one aspect of the present disclosure, there is provided a method of manufacturing a stator, including: an adjustment step of adjusting a thickness of a laminated body including a laminated group of soft magnetic alloy strips containing, in whole or in part, the soft magnetic alloy strips obtained by heat-treating amorphous alloy strips and metal plates, the metal plates sandwiching the laminated group; a winding step of fastening the laminated body to a base and performing winding at a predetermined position of the laminated body in a laminating direction; a removal step of releasing the fastening of the laminated body to the base and removing foreign matters from an end surface of the laminated body; and a fastening step of fastening the laminated body to the base again.

According to another aspect of the present disclosure, there is provided a stator including: a laminated group of soft magnetic alloy strips containing, in whole or in part, soft magnetic alloy strips obtained by heat-treating amorphous alloy strips; metal plates that sandwich the laminated group; a winding wound in a laminating direction at a predetermined position of the laminated body including the laminated group and the metal plates; a base that holds the laminated body; and a fastening mechanism that penetrates the laminated body in the laminating direction and fastens the base and the laminated body.

The motor according to one aspect of the present disclosure includes: a stator according to one aspect of the present disclosure; and a rotor.

According to the present disclosure, the characteristics and reliability of the motor can be ensured.

DESCRIPTION OF EMBODIMENTS

Hereinafter, each embodiment of the present disclosure will be described with reference to the drawings. In each drawing, common configuration elements will be given the same reference numerals, and the description thereof will be appropriately omitted.

First Exemplary Embodiment

A first exemplary embodiment according to the present disclosure will be described.

A structure of stator100according to the exemplary embodiment will be described with reference toFIGS. 1A and 1B.FIG. 1Ais a side view of stator100according to the first exemplary embodiment.FIG. 1Bis a top view ofFIG. 1A.

As illustrated inFIG. 1A, laminated body1is formed by sandwiching laminated group3of soft magnetic alloy strips with electromagnetic steel sheets2(an example of a metal plate).

As illustrated inFIG. 1B, winding13is provided so as to wind an insulated copper wire at a predetermined position of teeth14and tighten laminated body1in the laminating direction.

As illustrated inFIGS. 1A and 1B, in stator100, laminated body1provided with winding13is fixed by bolt4. Bolt4is inserted into through-holes (not illustrated) of spring washer5, washer6, and laminated body1, and is fastened to leg7of the base. The number of bolts4is, for example, four. Further, legs7of the base may be simply referred to as a “base”.

<Manufacturing Process of Stator>

A manufacturing process of stator100illustrated inFIGS. 1A and 1Bwill be described with reference toFIG. 2.FIG. 2is a flow chart illustrating an outline of the manufacturing process of stator100.

As illustrated inFIG. 2, the flow includes an adjustment step, a winding step, a removal step, and a fastening step. The outline of each step will be described below.

The adjustment step is a step of adjusting the thickness of laminated body1. In this adjustment step, first, the amorphous alloy strips are heat-treated to form soft magnetic alloy strips. Next, laminated group3of the soft magnetic alloy strips containing, in whole or in part, the soft magnetic alloy strips is formed. Next, electromagnetic steel sheets2are provided above and below (upper and lower sides in the drawing) of laminated group3of the soft magnetic alloy strips to form laminated body1. Next, the number of soft magnetic alloy strips is increased or decreased to adjust the thickness of laminated body1to a desired thickness. Details will be described below.

In the winding step, first, laminated body1of which the thickness has been adjusted in the adjustment step is fixed to legs7of the base by using a fastening mechanism (for example, bolt4, spring washer5, washer6, and the like). Specifically, as described above, bolt4is inserted into the through-hole (not illustrated) of spring washer5, washer6, and laminated body1and fastened to leg7of the base. Next, winding is performed in the laminating direction of fixed laminated body1. Specifically, as described above, the copper wire is wound around teeth14at a predetermined position, and laminated body1is tightened in the laminating direction.

In the removal step, first, bolt4is removed to release the fixing of laminated body1. Next, foreign matters (for example, powder or fragments) adhering to the end surface of laminated body1is removed.

In the fastening step, laminated body1of which the foreign matters are removed is fixed again to legs7of the base by using a fastening mechanism (for example, bolt4, spring washer5, washer6, and the like). Specifically, similar to the winding step, bolt4is inserted into the through-hole (not illustrated) of spring washer5, washer6, and laminated body1and fastened to leg7of the base. Therefore, the fastening step may be referred to as a “refixing step”.

The outline of each step has been described above. In the following, the adjustment step, the removal step, and the fastening step will be described in more detail.

The adjustment step will be described with reference toFIGS. 3A and 3B.FIG. 3Ais a side view of stator100during the adjustment step.FIG. 3Bis a top view ofFIG. 3A.FIGS. 3A and 3Bare different fromFIGS. 1A and 1Bin that winding13is not provided.

As described above, in the adjustment step, the soft magnetic amorphous alloy strips are heat-treated and then laminated to form laminated group3of the soft magnetic alloy strips, as illustrated inFIG. 3A. After laminating the soft magnetic amorphous alloy strips to form laminated group3of the soft magnetic alloy strips, laminated group3of the soft magnetic alloy strips is heat-treated, and accordingly, the laminated group3of the soft magnetic alloy strips illustrated inFIG. 3Amay be formed.

Laminated group3of the soft magnetic alloy strips is configured of the soft magnetic alloy strips in all or a part thereof. In a case where laminated group3of the soft magnetic alloy strips contains the soft magnetic alloy strips in a part thereof, the rest may contain the amorphous strips that are not heat-treated.

Further, as described above, in the adjustment step, the upper and lower sides of laminated group3of the soft magnetic alloy strips are sandwiched between electromagnetic steel sheets2to form laminated body1. Bolt4is inserted into each of spring washer5, washer6, and laminated body1in the laminating direction, and is fastened to leg7of the base with a preset fastening force.

At this time, a deformed part is generated in the soft magnetic alloy strips in the vicinity of the fastener (a part where bolt4is provided) as described with reference toFIG. 15B. Accordingly, the thickness (hereinafter, referred to as the laminated thickness) of laminated body1in the vicinity of spring washer5and washer6becomes small, and the laminated thickness other than in the vicinity of spring washer5and washer6becomes large.

Further, in a case where only the parts where the plate thickness of the soft magnetic alloy strips is small are laminated, the laminated thickness becomes small.

Here, a case where the laminated thickness becomes large and a case where the laminated thickness becomes small will be described with reference toFIGS. 4A and 4B.FIG. 4Ais a side view of a stator having a large laminated thickness, andFIG. 4Bis a side view of a stator having a small laminated thickness.

As illustrated inFIG. 4A, maximum laminated thickness part8is generated in the vicinity of the middle of two bolts4.

As illustrated inFIG. 4B, there are many cases where minimum laminated thickness part9generated by laminating the parts where the plate thickness of the soft magnetic alloy strip is small is also generated in the vicinity of the middle of two bolts4. However, since the distribution of the plate thickness of the soft magnetic alloy strip should also be considered, the place where minimum laminated thickness part9is generated is not always determined.

Further, the amount of increase or decrease in laminated thickness is not necessarily the same above and below laminated body1. When the difference between the amounts between the upper and lower sides is large, the accuracy of the appearance dimensions of the stator will deteriorate, and thus, the accuracy of assembling the motor will also deteriorate.

Further, in a case where the laminated thickness is large, when the gap between the soft magnetic alloy strips is large, the soft magnetic alloy strips that have been heat-treated and become brittle are present so as to be floating alone. Therefore, there is also a problem that the soft magnetic alloy strips are easily damaged.

Such a change in the laminated thickness can be suppressed by the rigidity of electromagnetic steel sheets2provided above and below laminated group3of the soft magnetic alloy strips.

Since the plate thickness of electromagnetic steel sheet2is limited, in a case where the rigidity or strength of only one electromagnetic steel sheet2is insufficient, a plurality of electromagnetic steel sheets2may be laminated.

Further, another metal plate may be used instead of electromagnetic steel sheet2. However, a soft magnetic metal plate is preferable. In a case where a metal plate other than the soft magnetic metal plate is used, the copper loss becomes large as the winding length becomes long, and the motor efficiency deteriorates.

In general, when producing the stator, the specification of the laminated thickness is within plus or minus several %. Further, by making the gap between the soft magnetic alloy strips to several μm or less, damage to the soft magnetic alloy strips after the heat treatment is prevented. Therefore, it is desirable that the change in the laminated thickness is within plus or minus 10%.

In order to keep the laminated thickness within plus or minus 10% of the preset specification value, for example, with respect to laminated body1illustrated inFIG. 4A or 4B, the laminated thickness is adjusted by repeating selection, combination, and increase and decrease of soft magnetic alloy strips having a different plate thickness distribution.

The above-described problem in adjusting the laminated thickness will be described with reference toFIG. 5.FIG. 5is a partial sectional view of laminated group3of the soft magnetic alloy strips during the adjustment of the laminated thickness and before bolt4is fastened.

When bolt4is loosely tightened, there is a case where gap12remains between the layers of soft magnetic alloy strips22, and end portion11of soft magnetic alloy strips is deformed and damaged. Accordingly, gap12is made as small as possible to prevent end portion11from being deformed due to vertical movement or displacement of soft magnetic alloy strips22.

Although necessary fastening force depends on the type of stator, the fastening force of bolt4needs to be 5 N m or more in order not to cause vertical movement or displacement. In order to improve the motor characteristics, it is necessary to increase the space factor, which is the proportion of soft magnetic alloy strips22occupying laminated group3of the soft magnetic alloy strips.

The space factor was 77 to 85% in the steps of the related art, but was improved to 83 to 99% in the removal step and the fastening step of the present exemplary embodiment.

The reason why the space factor does not reach 100% is considered that the plate thickness of soft magnetic alloy strip22is not constant over the entire surface, a gap is generated between soft magnetic alloy strips22, soft magnetic alloy strip22is chipped, and a part where soft magnetic alloy strip22is not present is generated within the dimensional specifications of stator100.

Laminated body1of which the thickness has been adjusted in the adjustment step as described above is fixed to legs7of the base by bolts4with a predetermined fastening force in the next winding step. Then, as illustrated inFIGS. 1A and 1B, winding13is wound around teeth14at a predetermined position, and laminated body1is tightened in the laminating direction.

The removal step will be described with reference toFIGS. 6A and 6B.FIG. 6Ais a side view of the stator after the winding step.FIG. 6Bis a top view ofFIG. 6A.

In the removal step, first, as illustrated inFIGS. 6A and 6B, all bolts4(refer toFIG. 3A) are removed, and laminated body1is removed from leg7of the base (refer toFIG. 3A). Accordingly, the fixing of laminated body1is released. Even when the fastening by bolt4is released, laminated body1is not disassembled because laminated body1is tightened by winding13.

Next, as illustrated inFIG. 6A, air16is blown from nozzle15to the end surface (outer peripheral surface) of laminated group3of the soft magnetic alloy strips at a predetermined pressure. Further, air16is blown not only to the end surface of laminated group3of the soft magnetic alloy strips, but also to the surface on the inner diameter side and the end surface of teeth14on which winding13is applied. Accordingly, foreign matters (for example, powder or fragments) that are present on the surface of stator100or between the layers of soft magnetic alloy strip22can be removed. The vicinity of fastening hole17illustrated inFIG. 6Bis a place where the stress generated at the time of fastening is large and foreign matters are particularly likely to be generated.

Since the tightening force is lost in the vicinity of fastening hole17, between the layers of the soft magnetic alloy strip in the vicinity of fastening hole17are slightly opened. Accordingly, even when there are foreign matters between the layers, it is easier to remove the foreign matters than when bolt4is fastened.

There are no particular restrictions on the method of removing the foreign matters. However, in the contact-type removal method using a brush or the like, there is a concern that the brush or the like may peel off and remain as a foreign matter on the stator side. Accordingly, a non-contact removal method such as blowing air16described above is preferable.

Non-contact removal methods other than blowing air16include, for example, a removal method using air suction and a removal method using magnet suction. Since the powder or fragments are minute and small in quantity, the rate of decrease in the space factor of the stator after the removal step was 1% or less, and the space factor number hardly changed significantly.

The fastening step is the same as the fastening step of bolt4in the above-described adjustment step. In other words, bolt4is inserted into each of spring washer5, washer6, and laminated body1in the laminating direction, and is fastened to leg7of the base with a preset fastening force. Accordingly, the production of stator100illustrated inFIGS. 1A and 1Bis completed.

Since tightening is performed with a preset fastening force in the adjustment step and foreign matters are removed in the removal step, the possibility that new foreign matters are present in stator100after the fastening step is low.

After the fastening step, a step of removing the foreign matters from the end surface of laminated body1may be performed again. However, in this case, the fixing of laminated body1is not released.

Further, even before the winding step, a step of removing the foreign matters from the end surface of laminated body1may be performed. In this case, the foreign matters that are present in the vicinity of winding13can be removed more reliably.

<State of End Surface of Laminated Group>

The state of the end surface of laminated group3of the soft magnetic alloy strips after the fastening step will be described in detail.FIG. 7Ais a front view illustrating an example of a part of the end surface of laminated group3of the soft magnetic alloy strips after the fastening step.FIG. 7Bis a sectional view ofFIG. 7A.

As illustrated inFIGS. 7A and 7B, in a case where soft magnetic alloy strip22ahaving a substantially uniform plate thickness and soft magnetic alloy strip22bhaving a thin part in the plate thickness are laminated, gap23is generated between the layers. Although not illustrated, a gap may be similarly generated even in a case where soft magnetic alloy strip22ahaving a substantially uniform plate thickness and soft magnetic alloy strip having a part with a thick plate thickness are laminated. In general, there are many cases where the plate thickness of soft magnetic alloy strip22is 0.02 mm to 0.06 mm.

There are many cases where a deviation of the plate thickness is set within plus or minus several % of the plate thickness. Further, the surface of soft magnetic alloy strip22has minute irregularities of 1 μm or less. In addition, there is also case where the minute holes may penetrate in the plate thickness direction. Due to these circumstances, a gap of 0.0001 mm to 0.06 mm is present at least at a part between the layers of soft magnetic alloy strip22on the end surface of laminated group3of the soft magnetic alloy strips.

An example of the end surface different from the end surface illustrated inFIGS. 7A and 7Bwill be described with reference toFIG. 8.FIG. 8is a sectional view illustrating an example of a part of the end surface of laminated group3of the soft magnetic alloy strips after the fastening step.

As illustrated inFIG. 8, in a case where soft magnetic alloy strip24having a chipped end part is present in the plurality of soft magnetic alloy strips22, gap25is generated on the end surface. The maximum gap that appears on the end surface is equivalent to the plate thickness. However, as illustrated inFIG. 8, in a case where the end parts of each of the soft magnetic alloy strips above and below gap25are tilted toward gap25, gap25that appears on the end surface becomes narrower than the plate thickness of soft magnetic alloy strip22.

Further, another example of the end surface will be described with reference toFIG. 9.FIG. 9is a sectional view illustrating an example of a part of the end surface of laminated group3of the soft magnetic alloy strips after the fastening step.

In the example ofFIG. 9, fragment26is present in gap27between soft magnetic alloy strip24having a chipped end part and the laminated end surface (the rightmost surface in the drawing). Fragment26is, for example, one that has not been removed by the removal step.

Even when fragment26that has not been removed in the removal step is present, since the compressive force acts in the laminating direction in the following fastening step, the possibility that fragment26falls off from the laminated end surface is substantially low.

Further, when the removal step is performed after the fastening step as described above, the possibility that fragment26falls off from the laminated end surface is further reduced.

Further, another example of the end surface will be described with reference toFIG. 10.FIG. 10is a sectional view illustrating an example of a part of the end surface of laminated group3of the soft magnetic alloy strips after the fastening step.

In the example ofFIG. 10, crack28is present in one of the plurality of soft magnetic alloy strips22.

Even when crack28or split are present in soft magnetic alloy strip22, the compressive force acts in the laminating direction in the fastening step, and thus deterioration of crack28or split can be suppressed. Accordingly, the possibility that the fragments generated by crack28or split fall off from the laminated end surface is low.

Further, another example of the end surface will be described with reference toFIGS. 11A and 11B.FIG. 11Ais a front view illustrating an example of a part of the end surface of laminated group3of the soft magnetic alloy strips after the fastening step.FIG. 11Bis a sectional view ofFIG. 11A.

Soft magnetic alloy strip22becomes brittle while being hardened by heat treatment. Accordingly, in a case where an object harder than soft magnetic alloy strip22hits the end surface of laminated group3of the soft magnetic alloy strips during the manufacturing process of stator100, for example, as illustrated inFIGS. 11A and 11B, there is a case where missing part29over a plurality of layers of soft magnetic alloy strip22occurs.

There is a case where powder or fragments remains in missing part29. Among these foreign matters, those that easily fall off from the laminated end surface are removed by the above-described removal step. Damage on the surface of missing part29is unlikely to proceed.

AlthoughFIGS. 11A and 11Billustrate a case where the boundary between the layers of soft magnetic alloy strip22is clear in missing part29, there can also be a case where the boundary may be unclear.

Motor200using stator100described above will be described with reference toFIGS. 12A and 12B.FIG. 12Ais a side view of motor200using stator100.FIG. 12Bis a top view ofFIG. 12A.

As illustrated inFIGS. 12A and 12B, motor200is completed by providing rotor18inside teeth14with respect to stator100produced by the series of manufacturing process described above. In motor200, when winding13is energized, rotor18is rotationally driven.

In the present exemplary embodiment, a case where rotor18is provided on the inner diameter side of stator100has been described as an example, but rotor18may be provided on the outer peripheral side of stator100.

As described above, in the method of manufacturing stator100of the present exemplary embodiment, first, the adjustment step of adjusting the thickness of laminated body1including laminated group3of soft magnetic alloy strips containing, in whole or in part, soft magnetic alloy strips22obtained by heat-treating amorphous alloy strips and metal plates (for example electromagnetic steel sheets2), the metal plates sandwiching laminated group3of soft magnetic alloy strips, is performed.

Next, the winding step of performing winding in the laminating direction at a predetermined position of laminated body1by fastening laminated body1to the base (for example, leg7of the base), is performed.

Next, the removal step of removing the foreign matters from the end surface of laminated body1by releasing the fixing of laminated body1to the base, is performed.

Next, the fastening step of fastening laminated body1to the base again, is performed. The stator is produced by these steps. A motor is produced using the stator.

Accordingly, it is possible to prevent fragments or the like of the soft magnetic alloy strips from falling off from the end surface of the laminated body. Therefore, the characteristics and reliability of the motor can be ensured.

Second Exemplary Embodiment

A second exemplary embodiment according to the present disclosure will be described.

A structure of stator110according to the present exemplary embodiment will be described with reference toFIGS. 13A and 13B.FIG. 13Ais a side view of motor210of the present exemplary embodiment.FIG. 13Bis a top view ofFIG. 13A.

Motor210illustrated inFIGS. 13A and 13Bis the same as motor200of the first exemplary embodiment illustrated inFIGS. 12A and 12B, except that the structure of laminated body31is different.

As illustrated inFIGS. 13A and 13B, laminated body31of the present exemplary embodiment includes laminated group34of soft magnetic alloy strips which are not heat-treated between laminated group33of the heat-treated soft magnetic alloy strips and electromagnetic steel sheet2.

The appearance of the soft magnetic amorphous alloy strips that are not heat-treated has a clear metallic luster. Meanwhile, the heat-treated soft magnetic alloy strip has a weak metallic luster due to being colored. Accordingly, it is possible to easily distinguish laminated group33of heat-treated soft magnetic alloy strips and laminated group34of soft magnetic alloy strips.

Next, the structure of the vicinity of the fastener (a part where bolt4is provided) of stator110described above will be described with reference toFIGS. 14A and 14B.FIG. 14Ais a front view of the vicinity of the fastener of stator110.FIG. 14Bis a sectional view ofFIG. 14A.

Laminated group34of the soft magnetic alloy strips that are not heat-treated as illustrated inFIG. 13Aincludes two soft magnetic amorphous alloy strips36that are not heat-treated as illustrated inFIGS. 14A and 14B.

Laminated group33of the heat-treated soft magnetic alloy strips illustrated inFIG. 13Aincludes a plurality of soft magnetic alloy strips35illustrated inFIGS. 14A and 14B. Soft magnetic alloy strip35is a heat-treated soft magnetic alloy strip.

At this time, the tightening force that acts on laminated group34of the soft magnetic alloy strips that are not heat-treated is the strongest immediately below electromagnetic steel sheet2. Here, since soft magnetic amorphous alloy strip36has high ductility, damage does not easily occur. Therefore, as illustrated inFIGS. 14A and 14B, it is preferable to arrange soft magnetic amorphous alloy strips36immediately below electromagnetic steel sheet2. In other words, soft magnetic amorphous alloy strip36is preferably provided so as to be in contact with electromagnetic steel sheet2.

In the examples ofFIGS. 14A and 14B, a case where there is gap37in laminated group33of the soft magnetic alloy strips obtained by heat-treating soft magnetic alloy strips35and fragment38of the soft magnetic alloy strips remains in gap37, is illustrated. In this case, as illustrated inFIGS. 14A and 14B, soft magnetic amorphous alloy strip36is also deformed according to the deformation of the end portion of electromagnetic steel sheet2. Accordingly, fragment38is pressed and restrained from the upper side in the drawing.

When fragment38remains after the removal step (removal work by air or magnet), fragment38receives the compressive force in the laminating direction in the fastening step, and thus, the possibility that the fragment falls off due to the drive of the motor is low.

Although the size of gap37should also be considered, as illustrated inFIGS. 14A and 14B, there is also a case where gap39remains between electromagnetic steel sheet2and soft magnetic amorphous alloy strip36.

The number of soft magnetic amorphous alloy strips36that form laminated group34of the soft magnetic alloy strips that are not heat-treated may be one. Soft magnetic amorphous alloy strip36can act a role of a cushioning material against the damage even when being at a position (for example, a position in laminated group33of the heat-treated soft magnetic alloy strips) other than the position immediately below or above electromagnetic steel sheet2.

The present disclosure is not limited to the description of each of the above-described exemplary embodiments, and various modifications can be made without departing from the spirit of the present disclosure.

INDUSTRIAL APPLICABILITY

According to the method of manufacturing a stator, the stator, and the motor of the present disclosure, the characteristics and reliability of the motor can be ensured. Furthermore, the stator of the present disclosure can be applied not only to motors but also to applications of magnetically applied electronic components such as transformers.

REFERENCE MARKS IN THE DRAWINGS

1LAMINATED BODY2ELECTROMAGNETIC STEEL SHEET3LAMINATED GROUP OF SOFT MAGNETIC ALLOY STRIPS4BOLT5SPRING WASHER6WASHER7LEG OF BASE8MAXIMUM LAMINATED THICKNESS PART9MINIMUM LAMINATED THICKNESS PART10PLUS OR MINUS11END PART12GAP13WINDING14TEETH15NOZZLE16AIR17FASTENING HOLE18ROTOR22SOFT MAGNETIC ALLOY STRIP22aSOFT MAGNETIC ALLOY STRIP22bSOFT MAGNETIC ALLOY STRIP23GAP24SOFT MAGNETIC ALLOY STRIP25GAP26FRAGMENT27GAP28CRACK29MISSING PART31LAMINATED BODY33LAMINATED GROUP OF HEAT-TREATED SOFT MAGNETIC ALLOY STRIPS34LAMINATED GROUP OF SOFT MAGNETIC ALLOY STRIPS THAT ARE NOT HEAT-TREATED35SOFT MAGNETIC ALLOY STRIP36SOFT MAGNETIC AMORPHOUS ALLOY STRIP37GAP38FRAGMENT39GAP40THROUGH-HOLE41LAMINATED GROUP OF SOFT MAGNETIC ALLOY STRIPS42BOLT43WASHER44LEG OF BASE45THROUGH-HOLE46SOFT MAGNETIC ALLOY STRIP47DEFORMED PART48GAP100STATOR110STATOR200MOTOR210MOTOR