Stator, motor, and air conditioner

A stator to which a power supply lead wire for supplying electric power is connected, includes a stator core, a winding wound around the stator core, a winding terminal connected to the winding, a circuit board connecting the power supply lead wire and the winding terminal to each other and having a surface facing the stator core, a power supply terminal provided on the surface and connected to the power supply lead wire, and a wiring pattern provided on the surface and connecting the winding terminal and the power supply terminal to each other.

CROSS REFERENCE TO RELATED APPLICATION

This application is a U.S. national stage application of International Patent Application No. PCT/JP2016/069126 filed on Jun. 28, 2016, the disclosure of which is incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to a stator, a motor, and an air conditioner.

BACKGROUND ART

In general, a stator of a motor includes a stator core, an insulation part covering teeth of the stator core, and a winding of each phase made of magnet wire wound around the teeth via the insulation part. In the stator of a motor, a printed circuit board having a wiring pattern for supplying electric power to a terminal of the winding of each phase is used. Patent Reference 1 describes a printed circuit board supporting device of a commutatorless motor, in which terminal pins are electrically connected to the wiring pattern of the printed circuit board by inserting support projections and the terminal pins into through holes of the printed circuit board.

PATENT REFERENCE

Patent Reference 1: Japanese Utility Model Application Publication No. 64-16181 (for example, Line 17 on Page 9 to Line 15 on Page 11)

However, in the device described in Patent Reference 1, a necessary wiring pattern is printed with copper foil and principal components forming a drive circuit, such as a driver IC, a transistor array and a power transistor, are arranged on a front surface of the printed circuit board, while Hall effect elements, capacitors and fixed resistors used for detecting the position of the rotor are arranged on a back surface of the printed circuit board. Therefore the printed circuit board is a double-sided board processed on both sides and there is a problem in that the manufacturing cost rises.

SUMMARY

The present invention has been made to resolve the above-described problem with the conventional technology, and the object of the present invention is to provide a stator, a motor and an air conditioner capable of reducing the manufacturing cost.

A stator according to an aspect of the present invention is a stator to which a power supply lead wire for supplying electric power is connected, comprising a stator core, a winding wound around the stator core, a winding terminal connected to the winding, a circuit board connecting the power supply lead wire and the winding terminal to each other and having a surface facing the stator core, a power supply terminal provided on the surface and connected to the power supply lead wire, and a wiring pattern provided on the surface and connecting the winding terminal and the power supply terminal to each other.

A motor according to another aspect of the present invention comprises the aforementioned stator, a rotor, and a support part to which the stator is fixed and which rotatably supports the rotor.

An air conditioner according to another aspect of the present invention is an air conditioner comprising a blower, wherein the blower includes the aforementioned motor.

According to the stator, the motor and the air conditioner according to the present invention, the effect of reducing the manufacturing cost can be obtained.

DETAILED DESCRIPTION

A stator100, a motor200and an air conditioner300according to embodiments of the present invention will be described below with reference to the drawings. An XYZ orthogonal coordinate system is shown in the drawings to facilitate the understanding of the relationship among the drawings. A Z-axis in the drawings is shown as a coordinate axis parallel to an axis line of the stator100. A Y-axis in the drawings is shown as a coordinate axis parallel to (or substantially parallel to) a lengthwise direction of a lead wire part10. An X-axis in the drawings is shown as a coordinate axis orthogonal to both the Y-axis and the Z-axis. In the drawings, the same components are assigned the same reference character as each other.

(1) First Embodiment

FIG. 1(a)is a top view showing a schematic configuration of a stator100(in a state in which a printed circuit board20is not attached thereto) according to a first embodiment of the present invention, andFIG. 1(b)is a side view showing a schematic configuration of the stator100(in the state in which the printed circuit board20is not attached thereto) according to the first embodiment of the present invention. As shown inFIG. 1(a), the stator100includes a stator core1, an insulation part2, windings3, terminals4a,4b,4cand4d, and pins5for fixing the circuit board.

The stator core1includes a plurality of electromagnetic steel sheets stacked in layers. The plurality of electromagnetic steel sheets has holes punched out in belt-like shapes, and the plurality of electromagnetic steel sheets stacked in layers are fixed together by means of crimping, welding, adhesion, or the like. The insulation part2is fixed to the stator core1by molding a thermoplastic resin such as PBT (polybutylene terephthalate) to be integral with the stator core1, or by attaching the molded thermoplastic resin to the stator core1. In regard to the winding3, a coil is formed by winding magnet wire around the insulation part2provided on a tooth of the stator100. Ends (end portions) of the magnet wire are lead to hook parts (coil tying parts) of the terminals4a,4b,4cand4dand joined to the hook parts by means of fusing (heat crimping), soldering, or the like. The stator core1is formed by bending a belt-like core made of a plurality of electromagnetic steel sheets stacked in layers, placing the ends of the core to face each other, and welding the facing parts1atogether.

As shown inFIG. 1(a), the terminals4a,4b,4cand4dare arranged on an outer wall of the insulation part2. As shown inFIG. 1(a), the terminals4a,4band4cof multiple phases (winding terminals) which are connected to ends of the windings3of the multiple phases (U-phase, V-phase and W-phase) respectively, are arranged on the outer wall of the insulation part2in an upper part (+Y direction side) of the stator core1, and the terminal4dis arranged on the outer wall of the insulation part in a lower part (−Y direction side) of the stator core1. The terminals4a,4band4care terminals used to supply electric power from a power supply respectively to the windings3of the multiple phases, and the terminal4dis a terminal used to form a neutral point. The number of the terminals is not limited to four. The terminal4dis not necessarily essential in a case where the neutral point connection is not made by using a terminal.

As shown inFIGS. 1(a) and 1(b), the pins5for fixing the circuit board are arranged at three positions on the insulation part2. The printed circuit board20is fixed to the stator100by inserting the pins5for fixing the circuit board into pin insertion holes23(second insertion holes) of the printed circuit board (circuit board)20. Incidentally, the number and the positions of the arrangement of the pins5for fixing the circuit board are not limited to those shown inFIG. 1(a)as long as the configuration enables the fixation of the printed circuit board20to the stator100.

FIG. 2is a top view showing a schematic configuration of the lead wire part10in the first embodiment. As shown inFIG. 2, the lead wire part10includes power supply lead wires11for supplying electric power to the coils, sensor lead wires12for sending signals to position detection circuits, a board-in connector13connected to ends of the power supply lead wires11, and a board-in connector14connected to ends of the sensor lead wires12. The board-in connector13is a connector for connecting the power supply lead wires11to the printed circuit board20. The board-in connector14is a connector for connecting the sensor lead wires12to the printed circuit board20. While three power supply lead wires11and five sensor lead wires12are shown in the first embodiment, the numbers of the power supply lead wires11and the sensor lead wires12are not limited to those shown inFIG. 2.

FIG. 3(a)is a top view (viewed in the −Z direction) showing a schematic configuration of the printed circuit board20in the first embodiment to which the lead wire part10is attached.FIG. 3(b)is a side view (viewed in the +Y direction) showing a schematic configuration of the printed circuit board20in the first embodiment to which the lead wire part10is attached.FIG. 3(c)is a bottom view (viewed in the +Z direction) showing a schematic configuration of the printed circuit board20in the first embodiment to which the lead wire part10is attached.

As shown inFIGS. 3(b) and 3(c), the printed circuit board20in the first embodiment is a printed wiring board including an insulated substrate201having a surface20aon the side of the stator core (a surface facing the stator core1) and a surface20bon the side opposite to the stator core and wiring patterns30a,30band30cformed on the surface20a. The printed circuit board20shown inFIG. 3(c)is a single-sided board in which the wiring patterns30a,30band30cand the position detection circuit are formed exclusively on the surface20aon the side of the stator core.

As shown inFIG. 3(a), the lead wire part10is attached to the surface20bof the printed circuit board20on the side opposite to the stator core via the board-in connectors13and14. As shown inFIG. 3(c), the board-in connector13connected to the ends of the power supply lead wires11is set on the surface20bof the printed circuit board20on the side opposite to the stator core, and a terminal13aprovided on the board-in connector13(referred to also as an electric power supply terminal or a power supply terminal) appears on the surface20aof the printed circuit board20on the side of the stator core via an insertion hole formed through the printed circuit board20. A plurality of terminals is provided as the terminal13a.

As shown inFIG. 3(c), a wiring pattern30a, a wiring pattern30band a wiring pattern30cfor supplying electric power (for power supply lead wires), electrically connecting the terminal13aof the board-in connector13to the terminals4a,4band4cconnected to the windings3, are formed on the surface20aof the printed circuit board20on the side of the stator core, and the terminal13aof the board-in connector13and the terminals4a,4band4cconnected to the windings3are electrically connected to each other by joining the terminal13aof the board-in connector13to the wiring patterns30a,30band30cfor supplying electric power by means of soldering.

As shown inFIGS. 3(a) and 3(c), the board-in connector14connected to the ends of the sensor lead wires12is set on the surface20bof the printed circuit board20on the side opposite to the stator core, and the a terminal14aprovided on the board-in connector14(sensor lead wire terminal) appears on the surface20aof the printed circuit board20on the side of the stator core via an insertion hole formed through the printed circuit board20. A plurality of terminals is provided as the terminal14a. Wiring patterns50for sensor lead wires, electrically connecting the terminal14aof the board-in connector14to Hall ICs (Hall Integrated Circuits)22as magnetic sensors used as the position detection circuits, are formed on the surface20aof the printed circuit board20on the side of the stator core (part of the wiring patterns50is not shown), and the terminal14aof the board-in connector14and the Hall ICs22are electrically connected to each other by joining the terminal14aof the board-in connector14to the wiring patterns50for sensor lead wires by means of soldering.

As shown inFIG. 3(a), a substrate retaining member24is arranged on the surface20bof the printed circuit board20on the side opposite to the stator core. The substrate retaining member24is formed by molding a thermoplastic resin such as PBT and has a configuration in which mold contact projections are connected together by thin-wall parts. When the stator100is formed by molding, the mold contact projections of the substrate retaining member24touch the mold, by which deformation of each wiring board can be prevented.

As shown inFIG. 3(c), on the surface20aof the printed circuit board20on the side of the stator core, the Hall ICs22as the position detection circuits for the rotor are formed at three positions. The Hall ICs22include a plurality of position detection circuits. Further, terminal insertion holes21a,21band21c(first insertion holes) as insertion holes for the terminals4a,4band4care formed at three positions.

FIG. 4(a)is a top view (viewed in the −Z direction) showing a schematic configuration of the stator100in the first embodiment to which the printed circuit board20is attached.FIG. 4(b)is a side view (viewed in the +Y direction) showing a schematic configuration of the stator100in the first embodiment to which the printed circuit board20is attached.FIG. 4(c)is a bottom view (viewed in the +Z direction) showing a schematic configuration of the stator100in the first embodiment to which the printed circuit board20is attached.

As shown inFIG. 4(a), the printed circuit board20to which the lead wire part10is attached is fixed to the stator100by inserting the pins5for fixing the circuit board into the pin insertion holes23of the printed circuit board20. At that time, the terminals4a,4band4care inserted into the terminal insertion holes21a,21band21cof the printed circuit board20and soldered. Further, as shown inFIG. 4(c), the Hall ICs22are arranged at positions where the position of the rotor can be detected.

FIG. 5(a)is a side view showing a schematic configuration of the terminal4ain the first embodiment.FIG. 5(b)is a front view showing a schematic configuration of the terminal4ain the first embodiment.FIG. 6is an enlarged side view showing a positional relationship among the terminals4a,4band4cand the printed circuit board20in the first embodiment. Incidentally, while the terminal4ais illustrated inFIGS. 5(a) and 5(b), the terminal4band the terminal4calso have substantially the same configuration.

As shown inFIG. 4andFIGS. 5(a) and 5(b), each terminal4a,4b,4cincludes a joint part41to be inserted into the terminal insertion hole21a,21bor21cof the printed circuit board20and a coil tying (winding) part42that is bent to be orthogonal to the axial direction of the stator100(Z direction). The joint parts41are parts formed in upper parts of the terminals4a,4band4c, and are inserted into the terminal insertion holes21a,21band21cof the printed circuit board20and electrically joined to wiring patterns of the printed circuit board20by soldering or the like. The coil tying (winding) parts42is a part formed by bending a part of each terminal4a,4b,4c, and is a part used for fixing the winding3by hooking the winding3on the part and winding the winding3around the part. A plurality of windings is provided as the winding3.

As shown inFIG. 6, the joint parts41of the terminals4a,4band4care inserted into and fixed to the terminal insertion holes21a,21band21cof the printed circuit board20. Further, the insulation part2located around the terminal and on a side opposite to the part where the coil tying part42is formed, includes a region2aformed to be relatively low compared to the insulation part2around the region2a. Thanks to the region2a, insertion of a soldering iron or the like is facilitated and workability of the soldering is improved. In other words, the outer wall of the insulation part2includes a first outer wall part2bsupporting the terminals4a,4band4cas winding terminals and a second outer wall part (concave region)2aarranged adjacent to the first outer wall part2b, and the height of the second outer wall part2ain the axial line direction of the stator100(Z direction) is lower than the height of the first outer wall part2bin the axial line direction.

FIG. 7(a)is a side view showing a schematic configuration of a terminal4ein a modification of the first embodiment.FIG. 7(b)is a front view showing a schematic configuration of the terminal4ein the modification of the first embodiment.FIG. 8is an enlarged side view showing a positional relationship between the terminal4eand the printed circuit board20in the modification of the first embodiment. InFIGS. 7(a) and 7(b), components identical or corresponding to those inFIGS. 5(a) and 5(b)are assigned the same reference characters as those inFIGS. 5(a) and 5(b). InFIG. 8, components identical or corresponding to those inFIG. 6are assigned the same reference characters as those inFIG. 6.

As shown inFIGS. 7(a) and 7(b), the terminal4ein the modification includes a surface44formed by bending a part of the terminal4eto be orthogonal to the axial direction of the stator100(Z direction). As shown inFIG. 8, the surface44of the bent part of the terminal4eis pressed against each wiring pattern30a,30b,30cof the printed circuit board20and electrically joined to each wiring pattern30a,30b,30cby soldering or the like. In other words, the terminal4ehas the surface44facing a wiring pattern for supplying electric power (e.g., the wiring patterns30a,30b,30cshown inFIG. 3(c)), and the surface44facing the wiring pattern is connected to the wiring pattern for supplying electric power in a state of being pressed against the wiring pattern for supplying electric power. According to the shape of the terminal4ein the modification, the terminal4edoes not project to the surface20bof the printed circuit board20on the side opposite to the stator core, and thus the need of forming the terminal insertion holes through the printed circuit board20is eliminated. Further, since the terminal4eand the printed circuit board20are joined together by surfaces, the terminal4ecan be fixed to the printed circuit board20more firmly. Furthermore, the need of outer cover resin, which used to be necessary for covering the terminals projecting from the printed circuit board20, can be eliminated and the manufacturing cost of the stator100can be reduced.

FIG. 9is a perspective view schematically showing the structure of the stator100according to the first embodiment after the molding. As shown inFIG. 9, the stator100after the molding is molded uniformly thanks to mold resin, and has an opening101at the center. Into the opening101, the rotor is inserted.

In the stator100according to the first embodiment, the printed circuit board20is configured by printing the wiring patterns30a,30band30con the surface20aof the printed circuit board20on the side of the stator core and electrically connecting the windings3wound around the stator core1and the wiring patterns30a,30band30cof the printed circuit board20to each other on the surface20aon the side of the stator core, which makes it possible to form the printed circuit board20as a single-sided board less expensive than a double-sided board and reduce the manufacturing cost of the stator100.

In the stator100according to the first embodiment, the printed circuit board20is provided with the Hall ICs22, as the position detection circuits detecting the magnetic flux of the rotor, on the surface20aof the printed circuit board20on the side of the stator core. According to this configuration, the position detection circuits are provided on the surface20aon the side of the stator core which is the same surface as the wiring patterns30a,30band30cfor supplying electric power, and accordingly, the printed circuit board20can be formed as a single-sided board and the manufacturing cost of the stator100can be reduced.

In the stator100according to the first embodiment, the printed circuit board20having the wiring patterns for supplying electric power to the windings3wound around the stator core1is provided and the electric joint parts between the printed circuit board20and the windings3wound around the stator core1are provided on the surface20aon the side of the stator core. This makes it possible to downsize or eliminate the components for joining the windings3to the printed circuit board20and reduce the manufacturing cost of the stator100.

In the stator100according to the first embodiment, the insulation part2located around the terminal and on the side opposite to the part where the coil tying part42is formed, includes the region2aformed to be relatively low compared to the insulation part2around the region2a. Accordingly, a soldering iron or the like can be inserted into the region2a, the joining of each terminal4a,4b,4cto the printed circuit board20is facilitated, and the workability is improved, by which the manufacturing cost of the stator100can be reduced.

(2) Second Embodiment

FIG. 10is a side view schematically showing a motor200according to a second embodiment of the present invention. As shown inFIG. 10, the motor200according to the second embodiment includes the stator100according to the first embodiment or its modification, a rotor110, and a support part to which the stator100is fixed and which supports the rotor110to be rotatable (e.g., to be rotatable by using a bearing). The rotor110rotates around an axis line AX. The support part includes a frame (body frame) and a bracket111that rotatably supports the rotor110, for example. The motor200has a waterproof cap112that inhibits penetration of water into the bearing and other parts of the motor200.

According to the motor200according to the second embodiment, an effect of reducing the manufacturing cost of the motor200can be obtained in addition to the effects obtained by the stator100described in the first embodiment.

FIG. 11is a diagram schematically showing a configuration of an air conditioner300according to a third embodiment of the present invention. As shown inFIG. 11, the air conditioner300includes an outdoor unit310, an indoor unit320, and refrigerant piping330for circulating a refrigerant between the outdoor unit310and the indoor unit320.

The outdoor unit310includes a compressor311, a heat exchanger312, a fan313, and a motor314for rotating the fan313. The motor314and the fan313constitute a blower for supplying air to the heat exchanger312. The indoor unit320includes a heat exchanger321, a fan322, and a motor323for rotating the fan322.

The motor323and the fan322constitute a blower for supplying air to the heat exchanger321. In the air conditioner300according to the third embodiment, at least one of the motor314and the motor323is formed by the motor200according to the second embodiment. In the air conditioner300according to the third embodiment, either of a cooling operation for blowing out cool air from the indoor unit320and a heating operation for blowing out warm air from the indoor unit320can be performed selectively. The air conditioner300according to the third embodiment can be configured in the same way as conventional air conditioners except that the motor200according to the second embodiment is employed as at least one of the motor314and the motor323.

According to the air conditioner300according to the third embodiment, an effect of reducing the manufacturing cost of the air conditioner300can be obtained in addition to the effects obtained by the stator100described in the first embodiment and the effects obtained by the motor200described in the second embodiment.

Incidentally, air conditioners to which the present invention is applicable are not limited to air conditioners for indoor use like that shown inFIG. 11. The present invention is applicable to various types of devices equipped with a motor, such as air conditioners for freezing warehouses and air conditioners for refrigerators.