Split core stator with terminal accommodating resin box

A stator of a rotary electrical machine, includes a core unit configured by a plurality of core assemblies each including a laminated steel plate, an insulator, and a coil; a bus ring facing the core unit; and an accommodating box arranged at the insulator, accommodating an end portion of the coil, and including radially inward and outward engaged portions, the insulator including radially inward and outward extending portions, the radially inward extending portion including a radially inward engagement portion about which the accommodating box rotates in a radial direction of the core unit from an initial attachment position to an attached position and which engages with the radially inward engaged portion, the radially outward extending portion including a radially outward engagement portion which engages with the radially outward engaged portion in accordance with the rotation of the accommodating box to move the accommodating box in the radial direction.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is based on and claims priority under 35 U.S.C. §119 to Japanese Patent Application 2011-273227, filed on Dec. 14, 2011, the entire content of which is incorporated herein by reference.

TECHNICAL FIELD

This disclosure relates to a stator of a rotary electrical machine for driving a rotor facing the stator in a radial direction.

BACKGROUND DISCUSSION

A known stator of a rotary electrical machine is disclosed in, for example, JP4073705B (which will be hereinafter referred to as Reference1). The stator according to Reference 1 includes plural split cores (core assemblies) around each of which a coil is wound and which are supported by a housing so as to form an annular shape. In the known stator, low-voltage-side and high-voltage-side terminals are attached to insulators insulating a laminated steel plate. Low-voltage-side and high-voltage-side end portions of the coil are connected to the low-voltage-side terminal and the high-voltage-side terminal, respectively. In addition, the low-voltage-side end portions of the respective coils of the split cores adjoining one another are electrically connected to one another by the low-voltage-side terminals. A groove portion, which is configured by a pair of vertical walls arranged next to each other so as to extend in a circumferential direction of the stator, is formed at an upper portion at an inner or outer circumferential side of each of the insulators that configure the split core. The grooves formed at the respective split cores adjoining one another are connected to one another, thereby forming a connected annular groove continuously extending in the circumferentially direction of the stator. The connected annular groove is filled with an insulating resin material.

In the stator according to Reference1, the insulating resin material is filled in the connected annular groove formed at the inner or outer circumferential side of the insulator, entirely along the circumferential direction. Accordingly, an amount of the insulating resin material filled (used) in the connected annular groove is large, therefore increasing manufacturing costs of the stator. Further, a space filled with the insulating resin material is large; therefore, it is difficult for small portions of the connected annular groove to be filled with the insulating resin material. Accordingly, the connected annular groove may not be surely or fully filled with the insulating resin material, resulting in an insulation failure of ends of the coil. Consequently, an appropriate operation of the rotary electrical machine may be inhibited. JP2010-233405A (which will be hereinafter referred to as Reference 2) discloses a known stator of a rotary electrical machine, which avoids an inappropriate operation of a rotary electrical machine because of the foregoing insulation failure (seeFIGS. 12 and 13).

As illustrated inFIGS. 12 and 13, a stator1Z disclosed in Reference2includes a core unit3Z in which plural split cores4Z are arranged in an annular shape. Each of the plural split cores4Z includes laminated steel plates40, an insulator41Z partially insulating the laminated steel plates40, a coil42wound around the insulator41Z, and a neutral point terminal44. Low-voltage-side end portions421of the coils42respectively wound around the split cores4Z are connected to one another by the neutral point terminals44. A bus ring5retaining wire segments53u,53v,53wis attached to an outer circumferential side of the core unit3Z; thereby, the wire segments53u,53v,53ware connected via electricity supply terminals54to high-voltage-side end portions422of the coils42, respectively.

Radially outward terminal-accommodating boxes511opened to an upper side of the stator1Z and to the split cores4Z is provided in a position facing the split cores4Z that are arranged at an upper side of the bus ring5in a state where the bus ring5is attached to the core unit3Z. Resin boxes43Z are arranged at an upper side of the insulators41Z of the split cores4Z, respectively. The resin boxes43Z include radially inward terminal-accommodating boxes431Z, respectively, opened to the upper side of the stator1Z and to the radially outward terminal-accommodating boxes511. The radially outward terminal-accommodating boxes511and the radially inward terminal-accommodating boxes431Z are aligned to along a circumferential direction of the core unit3Z so as to face one another, thereby forming plural terminal accommodating boxes6Z opened to the upper side of the stator1Z. A radially inward flange411Z and a radially outward flange413Z that extend in a vertical direction of the stator1Z and in the circumferential direction of the core unit3Z are formed at the insulator41Z so as to be positioned at an inner circumferential side of the core unit3Z and at the outer circumferential side of the core unit3Z in a state where the coil42of the insulator41Z is arranged between the radially inward and outward sides of the core unit3Z. Each of the resin boxes43Z is supported from a lower side thereof by the radially inward flange411Z and the radially outward flange413Z.

The low-voltage-side end portion421of the coil42is arranged at an upper side of side walls of the radially inward terminal-accommodating box431Z so as to extend between the side walls facing each other in a circumferential direction of the radially inward terminal-accommodating box431Z. A pair of wire engagement portions414Z protruding toward an upper side of the split core4Z and separating from each other in the circumferential direction of the core unit3Z is formed at an upper end of the radially outward flange413Z of the insulator41Z. The high-voltage-side end portion422of the coil42is provided so as to extend between the pair of wire engagement portions414Z. An insulating resin material is filled in each of the terminal accommodating boxes6Z in a state where a connected portion between the neutral point terminal44and the low-voltage-side end portion421of the coil42and a connected portion between the electricity supply terminal54and the high-voltage-side end portion422of the coil42are accommodated in the terminal accommodating box6Z. Two protruding walls438Z protruding toward a lower side of the split core4are formed at a radially inward side of a bottom portion435Z of the resin box43Z. Engagement projections438Za protruding radially inwardly are formed at respective lower ends of the protruding walls438Z. Two engagement holes412Z are formed at an upper portion of the radially inward flange411Z of the insulator41Z so as to penetrate through the radially inward flange411Z. The engagement projections438Za of the protruding walls438Z, respectively, are inserted in the engagement holes412Z; thereafter, the resin box43Z is rotated about the both engagement holes412Z from the upper side to the lower side of the split core4. Therefore, the resin box43Z is attached to the insulator41Z. The bottom portion435Z of the radially inward terminal-accommodating box431Z includes an extending bottom portion436Z that protrudes radially outwardly from the bottom portion435Z. In a state where the resin box43Z is in an attached position relative to the split core4Z, the extending bottom portion436Z is located adjacent to a bottom portion521(holding flange) of the radially outward terminal-accommodating box511to the extent that an outflow of the insulating resin material may not occur.

According to the stator1Z disclosed in Reference 2, the resin box43Z is rotated or moved from the upper side to the lower side of the split core4Z to be therefore attached to the insulator41Z. In such attaching method to attach the resin box43Z to the insulator41Z, an appropriate clearance needs to be provided between the extending bottom portion436Z of the radially inward terminal-accommodating box431Z and the bottom portion521of the radially outward terminal-accommodating box511. For example, in a case where the clearance is small, the resin box43Z may not be smoothly or easily attached to the insulator41Z because of a contact between components. Further, for example, in a case where the clearance is large, the insulating resin material may flow out from the clearance.

In addition, according to the stator1Z disclosed in Reference 2, the attaching operation of the resin box43Z to the insulator41Z is conducted in a state where the high-voltage-side end portion422of the coil42is positioned to extend between the pair of wire engagement portions414Z. Therefore, it is necessary for the resin box43Z to be moved from the upper side to the lower side of the split core4Z in a state where the extending bottom portion436Z of the radially inward terminal-accommodating box431Z is kept non-contact with the high-voltage-side end portion422. Consequently, the resin box43Z may not be easily attached to the insulator41Z.

A need thus exists for a stator of a rotary electrical machine, which is not susceptible to the drawbacks mentioned above.

SUMMARY

According to an aspect of this disclosure, a stator of a rotary electrical machine, includes a core unit configured by a plurality of core assemblies arranged in an annular shape, each of the core assemblies including a laminated steel plate, an insulator insulating a portion of the laminated steel plate, and a coil wound around the insulator, a bus ring formed in an annular shape to face the core unit, the bus ring supplying an electric power to the coil, and an accommodating box arranged at the insulator, accommodating an end portion of the coil, and including a radially inward engaged portion and a radially outward engaged portion, the stator generating a rotating magnetic field when the electric power is applied to the coil, the insulator including radially inward and outward extending portions positioned at radially inward and outward sides of the core unit relative to the coil in an extending manner to support the accommodating box, the radially inward extending portion including a radially inward engagement portion which serves as a rotation center about which the accommodating box rotates in a radial direction of the core unit from an initial attachment position to an attached position, and which engages with the radially inward engaged portion so that the accommodating box is movable relative to the insulator in the radial direction of the core unit in a state where the accommodating box is in the attached position, the radially outward extending portion including a radially outward engagement portion which engages with the radially outward engaged portion in accordance with the rotation of the accommodating box to move the accommodating box in the radial direction.

DETAILED DESCRIPTION

[First embodiment] A first embodiment of a stator of a rotary electrical machine (which will be hereinafter referred to as a stator1) will be described as follows with reference toFIGS. 1 to 8C. In the description, a vertical direction (upper and lower sides) of a split core4corresponds to a vertical direction (upper and lower sides) inFIG. 2. However, such direction does not necessarily correspond to an actual orientation of the stator1. A vertical direction (upper and lower sides) of a bus ring5corresponds to a vertical direction (upper and lower sides) inFIG. 7. However, such direction does not necessarily correspond to the actual orientation of the stator1. The vertical direction of the bus ring5illustrated inFIG. 7is identical to a direction of a central axis of a core unit3which will be described below. In addition, in the description, a circumferential direction and inner and outer circumferential sides (or radially outward and radially inward sides) correspond to a circumferential direction and inner and outer circumferential sides (or radially outward and radially inward sides) that are based on a central axis (the central axis of the core unit3) around which the plural split cores4(one of which is illustrated inFIG. 2) are arranged in an annular shape.

As illustrated inFIG. 1, the plural split cores (thirty split cores4in the first embodiment) corresponding to core assemblies are arranged at equal intervals on an inner circumferential surface of a stator housing2and are supported by the inner circumferential surface. The split cores4, around each of which a coil42is wound, are arranged in series with one another within the stator housing2so as to form the substantially annular shape, thereby configuring the core unit3. The core unit3and the bus ring5configure plural terminal accommodating boxes6. Each of the terminal accommodating boxes6is filled with an insulating resin material7. Each ofFIGS. 2 to 11illustrates a status before the terminal accommodating box6is filled with the insulating resin material7.

In addition, a rotor100, which faces the inner circumferential side of the core unit3, is shown inFIG. 1by a dashed line. The rotor100is not a component of the stator1. An electric power supplied from external terminals55u,55v,55wis applied to the split cores4to generate a rotating magnetic field at the core unit3, thereby rotating the rotor100relative to the stator1.

As illustrated inFIG. 2, the split core4includes an insulator41having a laminated steel plate40therewithin. The insulator41made of a synthetic resin material insulates the laminated steel plate40provided within the insulator41. A radially inward flange (radially inward extending portion)411extending in the vertical direction of the split core4and in the circumferential direction of the core unit3, is formed at a portion of the insulator41, which is located at a radially inward end of each of the split cores4in a state where the split cores4are held by the stator housing2. A pair of engagement holes (engagement receiving portions, radially inward engagement portions)412is formed at an upper portion of the radially inward flange411. The engagement holes412penetrate through the radially inward flange411. The engagement holes412are formed so as to separate from each other by a predetermined distance in a circumferential direction of the stator housing2in a state where the split cores4are held by the stator housing2.

A radially outward flange (radially outward extending portion)413extending in the vertical direction of the split core4and in the circumferential direction of the core unit3so as to face radially outwardly relative the radially inward flange411, is formed at a portion of the insulator41, which is located at a radially outward end of each of the split cores4in a state where the split cores4are held by the stator housing2. A pair of wire engagement portions414is formed at an upper end portion of the radially outward flange413so as to extend upwardly. The pair of wire engagement portions414extending upwardly is positioned so as to separate from each other by a predetermined distance in the circumferential direction. A holding slit414aextending in the circumferential direction is formed in an upper end portion of each of the wire engagement portions414. Further, a hook portion416is formed at an upper end of the radially outward flange413so as to be positioned adjacent to a side of one of the wire engagement portions414in the circumferential direction. The hook portion416is formed into a substantially vertically-reversed L-shape opened outward from the wire engagement portion414, which is adjacent to the hook portion416, in a circumferential direction of the split core4.

As illustrated inFIG. 3, a support portion (radially outward engagement portion)415supporting a radially outward side of a resin box43which will be described below, from the lower side of the split core4is arranged between the wire engagement portions414formed at the upper end portion of the radially outward flange413. An inclined surface415ainclined obliquely upwardly from a radially outward side to a radially inward side of the split core4(of the core unit3) is formed at an upper end of the support portion415so as to face upward (seeFIG. 8A), i.e., the inclined surface415ais formed so as to be inclined toward the radially inward side as being away from the coil42.

A pair of retainers417protruding upwardly is formed at a portion of the insulator41, which is located at the radially outward end of each of the split cores4in a state where the split cores4are held by the stator housing2. The retainers417are positioned at the insulator41so as to separate from each other by a predetermined distance in the circumferential direction. The retainers417face the resin box43which will be described below, in a radial direction of the stator1. A bus ring insertion portion418is formed between the retainers417and the radially outward flange413in the radial direction of the stator1.

The coil42formed, for example, by an enamel wire, is wound around a portion between the radially inward flange411and the radially outward flange413of the insulator41. A high-voltage-side end portion422of the coil42wound on the insulator41is engaged with the hook portion416. Afterward, the high-voltage-side end portion422is bent reversely to be inserted in the holding slits414aof the wire engagement portions414, therefore extending between the wire engagement portions414(seeFIG. 2).

According to the first embodiment, the resin box43, made of, for example, aromatic nylon, polyphenylene sulfide resin, or the like, is formed to be a single-piece member having a substantially container shape. As illustrated inFIG. 2, the resin box43includes a radially inward terminal-accommodating box (accommodating box)431opened to the upper side of the split core4(to an opposite direction from the coil42in the vertical direction inFIG. 2) and to the radially outward side (to a radially outward terminal-accommodating box511which will be described below). The radially inward terminal-accommodating box431forms a radially inward accommodating space located at an inward side of the terminal accommodating box6in a radial direction of the core unit3. As illustrated inFIG. 5, the radially inward terminal-accommodating box431has a substantially U-shape in a planar view. The accommodating space formed within the radially inward terminal-accommodating box431forms a substantially cuboid which has a long side along the radial direction of the stator1and surrounded by a bottom portion435, a radially inward wall432formed to stand upwardly from a radially inward end portion of the bottom portion435, a pair of side walls433,434formed to stand upwardly from circumferential end portions of the bottom portion435(seeFIGS. 2 and 3). The resin box43is configured to be attachable to and detachable from an upper portion of the insulator41.

Stepped portions433a,434aare formed at radially outward end portions of the side walls433,434so as to increase a distance between the side walls433,434in the circumferential direction. Further, wire holding grooves433b,434bopened upward are formed at intermediate portions of the side walls433,434, respectively in the radial direction of the core unit3. Furthermore, terminal attachment portions437are formed at circumferential end portions of the side walls433,434so as to extend outwardly therefrom in the circumferential direction. Each of the terminal attachment portions437is formed by a pair of holding walls437aextending vertically and in parallel to each other. A clearance penetrating through each of the side walls433,434is formed between the holding walls437afacing each other in such a way that a neutral point terminal44(which will be described below) may be inserted in the clearance.

Moreover, a pair of protruding walls438(radially inward engaged portions) is formed at a radially inward side of the side walls433,434so as to protrude in parallel to each other and downwardly from lower ends of the bottom portion435in the circumferential direction (seeFIGS. 3 and 8). A pair of engagement protrusions (engagement protruding portions)438ais formed at respective lower ends of the protruding walls438so as to protrude radially inwardly. Each of the engagement protrusions438ahas the same wall thickness as each of the protruding walls438. The engagement protrusion438ais formed in a protruding shape that is separated from the bottom portion435. In addition, a pair of leg portions439protruding downwardly from the lower ends of the bottom portion435in the circumferential direction is formed at the respective circumferential end portions of the side walls433,434(seeFIG. 8).

As illustrated inFIG. 2, the bottom portion435includes an extending bottom portion (radially outward engaged portion)436that is formed so as to extend radially outwardly to a boundary line between the split core4and the bus ring5(so as to extend radially outwardly to a position adjacent to a radially outward end portion of each of the wire engagement portions414) in a state where the resin box43is attached to the upper portion of the insulator41. A width of the extending bottom portion436in the circumferential direction is slightly smaller than a distance of a clearance between the pair of wire engagement portions414of the insulator41in the circumferential direction; thereby, the extending bottom portion436is configured to be insertable between the pair of wire engagement portions414. A protruding portion436ais formed at a radially outward end portion of the extending bottom portion436so as to protrude downwardly therefrom. An inclined surface436binclined obliquely upwardly from the radially outward side to the radially inward side of the split core4is formed at a lower end of the protruding portion436aso as to face downward (seeFIGS. 8A,8B, and8C).

As illustrated inFIG. 2, the resin box43is attached to the upper portion of the insulator41on which the coil42is wound, therefore configuring the split core4. With reference toFIGS. 8A,8B, and8C, an attaching method to attach the resin box43to the insulator41of the split core4(to attach the radially inward terminal-accommodating box431to the insulator41) will be described as follows.FIG. 8Aillustrates a state where the resin box43starts rotating downwardly from an initial attachment position. The pair of engagement protrusions438aof the resin box43is deeply inserted in a movable manner into the pair of engagement holes412formed in the radially inward flange411of the insulator41, from the radially inward side to the radially outward side in a state where the resin box43is kept inclined as illustrated inFIG. 8A.

In a state where the pair of engagement protrusions438aof the resin box43is deeply inserted in the pair of engagement holes412, a radially inward end portion of each of the pair of protruding walls438formed at the resin box43is brought into contact with a radially outward edge of each of the pair of engagement holes412; thereby, the resin box43is restricted from moving radially inwardly relative to the radially inward flange411and is allowed to move radially outwardly from the radially inward flange411. In addition, a lower end of each of the pair of leg portions439formed at the resin box43is supported by an upper end of the radially inward flange411from a lower side of the leg portion439. As indicated by an arrow inFIG. 8A, the resin box43may be rotated around a portion in the vicinity of the engagement hole412from the initial attachment position at the upper side inFIG. 8Ato an attached position located at a lower side of the initial attachment position inFIG. 8Ain a condition where a radially inward position of the resin box43is determined as described above. As illustrated inFIG. 8A, in the midst of the rotation of the resin box43from the initial attachment position to the attachment position, the extending bottom portion436does not make contact with the high-voltage-side end portion422that is arranged so as to extend between the wire engagement portions414.

FIG. 8Billustrates a state where the resin box43is being guided to move radially outwardly. When the resin box43moves downwardly, the inclined surface415aformed at the support portion415of the radially outward flange413starts making contact with the inclined surface436bformed at the protruding portion436aof the extending bottom portion436of the resin box43, as illustrated inFIG. 8B. In accordance with the downward rotation of the resin box43, the inclined surface415aand the inclined surface436bslidably contact each other and are thereafter engaged with each other. As a result, the resin box43is guided to move radially outwardly as indicated by an arrow inFIG. 8B.

FIG. 8Cillustrates a state where the resin box43is completely attached to the insulator41of the split core4. At the radially outward side of the resin box43, the inclined surface415aand the inclined surface436bare entirely engaged with each other when the resin box43is arranged in the attached position as shown inFIGS. 2 and 8C. In addition, at the radially outward side of the resin box43, the extending bottom portion436is supported from a lower side thereof by the support portion415and the radially outward end portion of the extending bottom portion436is positioned in the vicinity of the boundary line between the split core4and the bus ring5. Furthermore, the stepped portions433a,434aof the side walls433,434are engaged with the wire engagement portions414from an outer side thereof in the circumferential direction (seeFIG. 2). Meanwhile, at the radially inward side of the resin box43, the pair of leg portions439is supported from a lower side thereof by the upper end of the radially inward flange411when the resin box43is arranged in the attached position as illustrated inFIG. 8C. In addition, at the radially inward side of the resin box43, the pair of engagement protrusions438ais inserted in a movable manner into the pair of engagement holes412so as to be shallowly engaged therewith.

After the resin box43is attached to the insulator41, a low-voltage-side end portion (end portion)421of the coil42is inserted in the wire holding groove433bof the side wall433to be thereafter engaged with the wire holding groove434bof the side wall434as illustrated inFIG. 5. Therefore, the low-voltage-side end portion421is positioned so as to extend between the side walls433,434. Afterward, as illustrated inFIG. 1, all of the split cores4are attached to the inner circumferential surface of the stator housing2so as to be arranged in the annular shape.FIG. 4is a partial perspective view illustrating a peripheral area of the external terminals55u,55v,55wof the stator1shown inFIG. 1, as seen from upper and outer circumferential sides of the stator1.FIG. 5is a partial plan view of a portion positioned radially opposite from the portion illustrated inFIG. 4, as seen from the upper side from the stator1.

As illustrated inFIGS. 4 and 5, the neutral point terminals44each serving as a low-voltage-side terminal are respectively attached to the resin boxes43of the core unit3configured by the split cores4arranged in the annular shape. Each of the neutral point terminals44is made of metal having electric conductivity. The neutral point terminal44includes an intermediate protruding portion441, an intermediate connecting piece442formed at an intermediate position of the intermediate protruding portion441in the circumferential direction, insertion portions443each having a linear shape, end portions444, and a pair of end portion connecting pieces445. The intermediate connecting piece442is provided at an intermediate position of the neutral point terminal44in a longitudinal direction thereof. When seen in a planar view, the neutral point terminal44is symmetrically shaped about the intermediate protruding portion441. The intermediate protruding portion441protrudes radially outwardly in a state where the neutral point terminal44is attached to the resin box43. The insertion portions443are connected to both ends of the intermediate protruding portion441. The end portions444protruding radially outwardly are formed at the insertion portions443, respectively. The end portion connecting pieces445are formed at respective ends of the end portions444.

The insertion portions443of the neutral point terminal44are inserted between the holding walls437aof the resin boxes43arranged adjacent to one another, thereby being attached to the three adjacent resin boxes43. Consequently, the intermediate connecting piece442and the pair of end portion connecting pieces445are arranged within the respective resin boxes43of the three split cores4arranged adjacent to one another. The intermediate connecting piece442and the end portion connecting pieces445are fixed to the corresponding low-voltage-side end portions421of the coils42, each of which is arranged so as to extend between the side walls433,434, by means of fusing, swaging, welding, and the like. As a result, the low-voltage-side end portions421of the coils42are connected to one another. All of the neutral point terminals44are connected to a low-voltage side of an inverter.

Each ofFIGS. 6 and 7illustrates the bus ring5and shows a state where one of the thirty electricity supply terminals54which will be described below is not attached to the bus ring5. As illustrated inFIG. 6, the bus ring5is formed into an annular shape so as to face the radially outward side of the core unit3. The bus ring5includes an outer clip51and an inner clip52that are made of synthetic resin material. The outer clip51and the inner clip52each formed into an annular shape are radially engaged with each other. Each of the outer clip51and the inner clip52may be configured by plural separate segments that are connected to one another.

As illustrated inFIGS. 1,4, and6, the external terminals55u,55v,55wto be connected to corresponding phases of a high-voltage side of the inverter extend from three portions of the outer clip51. The external terminals55u,55v,55ware connected to the electricity supply terminals54(each serving as a high-voltage-side terminal) of corresponding phases. Alternatively, the external terminals55u,55v,55wand the corresponding electricity supply terminals54may be integrally formed with one another.

The bus ring5further includes the plural wire segments53u(each serving as an electricity supply wire), the plural wire segments53v(each serving as an electricity supply wire), and the plural wire segments53w(each serving as an electricity supply wire) for corresponding phases. Each of the wire segments53u,53v,53w, for example, made of an enamel wire is formed into a substantially circular arc. The bus ring5made of metal having electric conductivity further includes the electricity supply terminals54swaged respectively to the wire segments53uin a pair, the wire segments53vin a pair, the wire segments53win a pair (seeFIG. 7).

A pair of annular ribs positioned in a vertical direction of the bus ring5is formed at an inner circumferential surface of the outer clip51so as to protrude radially inwardly. A pair of annular ribs positioned in the vertical direction of the bus ring5is formed at an outer circumferential surface of the inner clip52so as to protrude radially outwardly. When the outer clip51and the inner clip52are fitted to and engaged with each other, an inside of the bus ring5is divided by the annular ribs of the outer clip51and the annular ribs of the inner clip52into three portions in the vertical direction. Different phases are retained in respective spaces of the three divided portions of the inside of the bus ring5so as not to contact one another.

End portions of the pair of wire segments53uhaving the same phase, end portions of the pair of wire segments53vhaving the same phase, and end portions of the pair of wire segments53whaving the same phase extend upwardly and the end portions in each pair of wire segments53u,53v,53ware swaged by the electricity supply terminal54so as to be connected to each other. The electricity supply terminal54includes a swaging portion541swaged to the end portions in each pair of the wire segments53u,53v,53w, and a coil engagement portion542which extends to a radially inward side of the bus ring5. An end of the coil engagement portion542is configured to extend upward and subsequently extend downward, thereby being formed in a substantially reversed U-shape (seeFIG. 7).

As illustrated inFIGS. 5 and 7, the plural radially outward terminal-accommodating boxes511(the thirty radially outward terminal-accommodating boxes511) are arranged at equal intervals on an upper surface of the outer clip51in a circumferential direction thereof. Each of the radially outward terminal-accommodating boxes511is formed so as to have a substantially container shape opened upward (to the opposite direction from the coil42) and radially inward (to the radially inward terminal-accommodating box431). The radially outward terminal-accommodating box511forms a radially outward accommodating space located at an outward side of the terminal accommodating box6in the radial direction of the core unit3. The radially outward terminal-accommodating box511is formed by a radially outward wall512positioned at a radially outward side of the bus ring5, a pair of side walls513extending radially inwardly from circumferential ends of the radially outward wall512, a holding piece514for holding the outer clip51, and a holding flange521for holding the inner clip52. The holding piece514and the holding flange521correspond to a bottom portion of the radially outward terminal-accommodating box511. Respective end portions of the side walls513are opened; thereby, the radially outward terminal-accommodating box511has a trapezoidal shape in a planar view.

A terminal hole512athrough which each of the external terminals55u,55v,55wis pulled radially outwardly is formed at a lower side of the radially outward wall512(seeFIG. 7). In particular, the terminal hole512ais formed in an inner circumferential surface of the radially outward wall512. Further, as illustrated inFIGS. 5 and 7, the holding piece514protruding radially inwardly is formed at the inner circumferential surface of the radially outward wall512so as to be positioned at a lower side of the terminal hole512a. The holding piece514has a trapezoidal shape in a planar view and each of the wire segments53u,53w,53vis held by a radially inward end portion of the holding piece514.

As illustrated inFIGS. 5 and 7, the plural holding flanges521protruding radially outwardly are arranged at equal intervals on an upper end of the inner clip52in a circumferential direction thereof. Each of the holding flanges521having a trapezoidal shape in a planar view is fitted to the inner circumferential surface of the radially outward terminal-accommodating box511. A cutout portion521a having a trapezoidal shape is formed at a radially outward side of the holding flange521. The holding piece514is fitted to the cutout portion521aof the holding flange521. The end portions of the pair of wire segments53u, the end portions of the pair of wire segments53w, and the end portions of the pair of wire segments53vare held by corresponding radially inward end portions of the cutout portions521a. In addition, a pair of holding protrusions521bis formed on the holding flange521. The coil engagement portion542of the electricity supply terminal54is held by the holding protrusions521bso as to be fitted therebetween.

The outer clip51and the inner clip52are fitted to and engaged with each other, thereby forming the plural radially outward terminal-accommodating boxes511. In addition, as illustrated inFIG. 7, the electricity supply terminals54each swaged to the pair of wire segments53u, the pair of wire segments53v, and the pair of wire segments53ware surrounded by the radially outward terminal-accommodating boxes511, respectively. The end portions of the pair of wire segments53uhaving the same phase, the end portions of the pair of wire segments53vhaving the same phase, and the end portions of the pair of wire segments53whaving the same phase are located at every third position on the upper surface of the outer clip51in the circumferential direction thereof so as to protrude upward within the corresponding radially outward terminal-accommodating boxes511. In addition, the holding piece514of each of the radially outward terminal-accommodating boxes511is fitted to and engaged with the cutout portion521aof the inner clip52; thereby, a clearance is generated between the radially inward end portion of the holding piece514and the radially inward end portion of the cutout portion521a. The end portions of the pair of wire segments53u, the end portions of the pair of wire segments53v, and the end portions of the pair of wire segments53ware inserted in the corresponding clearances between the radially inward end portions of the holding pieces514and the radially inward end portions of the cutout portions521aand are held by the corresponding clearances.

In order to attach the bus ring5to the core unit3held by the stator1, the bus ring5is provided so as to face the core unit3from an upper side thereof as illustrated inFIG. 4. Then, the bus ring5is inserted in the bus ring insertion portions418of the split cores4, respectively. Therefore, a position of the radially outward wall512of each of the radially outward terminal-accommodating boxes511of the bus ring5is determined in such a way that the radially outward wall512is arranged between the pair of retainers417of the insulator41in the circumferential direction. At this time, radially inward end portions of the side walls513of the radially outward terminal-accommodating box511face the radially outward end portions of the side walls433,434of the resin box43from the radially outward side of the bus ring5while the wire engagement portions414of the split core4are positioned between the radially inward end portions of the side walls513in the circumferential direction.

Thus, the radially outward terminal-accommodating boxes511and the radially inward terminal-accommodating boxes431are aligned along the circumferential direction of the bus ring5so as to face radially each other in a state where the wire engagement portions414are provided between the radially outward terminal-accommodating boxes511and the radially inward terminal-accommodating boxes431. As a result, the terminal accommodating boxes6each having the container shape which is opened upward and which includes a predetermined volume, are separately formed at the split cores4. In the terminal accommodating box6, the coil engagement portion542of the electricity supply terminal54is engaged with the high-voltage-side end portion422of the coil42that is arranged so as to extend between the wire engagement portions414. Thereafter, the coil engagement portion542is fixed to the high-voltage-side end portion422by means of fusing, swaging, welding, and the like.

The insulating resin material7serving as a potting material is filled in each of the terminal accommodating boxes6in a state where a connected portion between the neutral point terminal44and the low-voltage-side end portion421of the coil42and a connected portion between the electricity supply terminal54and the high-voltage-side end portion422of the coil42are accommodated in the terminal accommodating box6(seeFIG. 1). The insulating resin material7includes predetermined viscosity. Therefore, for example, even in a case where small clearances are generated between the radially inward terminal-accommodating box431and the wire engagement portions414and between the radially outward terminal portion511and the wire engagement portions414at the timing of filling the insulating resin material7in the terminal accommodating boxes6, the insulating resin material7does not flow out of the terminal accommodating boxes6. The insulating resin material7filled in the terminal accommodating boxes6is solidified; thereby, the insulators41, the resin boxes43, and the bus ring5are fixed to one another to therefore complete the stator1.

In the stator1, an electric power is applied from the external terminals55u,55v,55wvia the wire segments53u,53u,53vto the coils42of each phase, thereby generating a rotating magnetic field.

According to the first embodiment, in order to attach the resin box43including the radially inward terminal-accommodating box431to the upper portion of the insulator41, firstly, the pair of engagement protrusions438aintegrally formed with the radially inward terminal-accommodating box431is inserted in a movable manner into the pair of engagement holes412formed in the radially inward flange411of the insulator41; thereby, the radially inward position of the radially inward terminal-accommodating box431is determined. Then, the radially inward terminal-accommodating box431is rotated from the initial attachment position to the attached position. Therefore, the inclined surface436bformed at the protruding portion436aof the extending bottom portion436of the radially inward terminal-accommodating box431slidably contacts the inclined surface415aformed at the support portion415of the radially outward flange413in accordance with the rotation of the radially inward terminal-accommodating box431and is thereafter engaged with the inclined surface415a. As a result, the resin box43including the radially inward terminal-accommodating box431is guided to move radially outwardly and thus the radially inward terminal-accommodating box431may be arranged adjacent to the radially outward terminal-accommodating box511in a state where the radially inward terminal-accommodating box431is in the attached position (i.e., in a state where the radially inward terminal-accommodating box431is attached to the insulator41).

Accordingly, for example, a clearance from which the insulating resin material7may flow is generated between the radially inward terminal-accommodating box431and the radially outward terminal-accommodating box511until just before the radially inward terminal-accommodating box431is rotated to the attached position. Even in such case, the radially inward terminal-accommodating box431is rotated to the attached position to therefore move radially outwardly toward the radially outward terminal-accommodating box511. As a result, the clearance is reduced. Thus, according to the first embodiment, in the case of attaching the radially inward terminal-accommodating box431(i.e., the resin box43) to the insulator41, a contact of the radially inward terminal-accommodating box431with the radially outward terminal-accommodating box511is of no concern and the radially inward terminal-accommodating box431(i.e., the resin box43) may be easily attached to the insulator41. Further, in a state where the radially inward terminal-accommodating box431(i.e., the resin box43) is attached to the insulator41, the radially inward terminal-accommodating box431and the radially outward terminal-accommodating box511are positioned adjacent to one another; therefore, the insulating resin material7does not flow out from a bottom portion of the terminal accommodating box6and the like.

Further, according to the first embodiment, the inclined surface415aformed at the radially outward flange413and the inclined surface436bformed at the radially inward terminal-accommodating box431are configured to be inclined obliquely upwardly from the radially outward side to the radially inward side. As a result, the radially inward terminal-accommodating box431may be moved radially in accordance with the rotation thereof by a simple configuration. Furthermore, according to the first embodiment, two members of the extending bottom portion436of the radially inward terminal-accommodating box431and the support portion415of the radially outward terminal-accommodating box511may easily or simply establish the engagement between the inclined surface415aand the inclined surface436band may surely support a radially outward side of the bottom portion435of the radially inward terminal-accommodating box431.

Moreover, according to the first embodiment, the engagement protrusions438aformed at the radially inward terminal-accommodating box431are inserted in a movable manner into the engagement holes412formed in the radially inward flange411of the insulator41. As a result, such simple configuration restricts the radially inward terminal-accommodating box431from moving radially inwardly relative to the radially inward flange411and allows the radially inward terminal-accommodating box431to move radially outwardly, thereby supporting the radially inward terminal-accommodating box431; thereby, the radially inward terminal-accommodating box431may be supported so as to move radially. In addition, in a state where the radially inward terminal-accommodating box431is attached to the insulator41, the engagement protrusions438aare shallowly inserted in a movable manner into the engagement holes412. Therefore, the radially inward terminal-accommodating box431is restricted from loosening from the radially inward flange411of the insulator41. As a result, in the first embodiment, the radially inward terminal-accommodating box431may be appropriately attached to the insulator41and may be surely held in the attached position.

Additionally, according to the first embodiment, the attaching operation of the radially inward terminal-accommodating box431to the insulator41is conducted in a state where the high-voltage-side end portion422of the coil42is arranged to extend between the pair of wire engagement portions414. However, in the midst of the rotation of the radially inward terminal-accommodating box431from the initial attachment position to the attached position, the extending bottom portion436of the radially inward terminal-accommodating box431does not make contact with the high-voltage-side end portion422arranged to extend between the pair of wire engagement portions414. Therefore, in the first embodiment, a contact of the radially inward terminal-accommodating box431with the high-voltage-side end portion422is of no concern and the radially inward terminal-accommodating box431may be easily attached to the insulator41.

[Second embodiment] A second embodiment of the disclosure will be described as follows with reference toFIGS. 9A,9B, and9C. In the second embodiment, the split core4in the stator1according to the first embodiment is modified to a split core4B corresponding to the core assembly. Other components and the like of the second embodiment are substantially the same as those of the first embodiment, and the description thereof is therefore omitted. In addition, components configuring the split core4B and being the same as those of the split core4in the stator1of the first embodiment are designated by the same reference numerals and the description thereof is partially omitted.

FIG. 9Aillustrates a state where a resin box43B rotates downwardly from an initial attachment position to an attached position.FIG. 9Billustrates a state where the resin box43B is being guided to move radially outwardly.FIG. 9Cillustrates a state where the resin box43B is completely attached to an insulator41B.

As illustrated inFIGS. 9A,9B, and9C, a radially inward flange (radially inward extending portion)411B extending in a vertical direction of a split core4B and in the circumferential direction of the core unit3, is formed at a portion of the insulator41B, which is located at a radially inward end of the split core4B. A pair of engagement grooves (engagement receiving portions, radially inward engagement portions)412B is formed at an upper portion of the radially inward flange411B. Each of the engagement grooves412B is a groove recessed downwardly from an upper end of the radially inward flange411B and penetrating through the radially inward flange411B in the radial direction of the core unit3. The engagement grooves412B are formed so as to separate from each other by a predetermined distance in the circumferential direction of the stator housing2in a state where the split cores4B are held by the stator housing2.

A radially outward flange (radially outward extending portion)413B extending in the vertical direction of the split core4B and in the circumferential direction of the core unit3so as to face radially outwardly relative the radially inward flange411B, is formed at a portion of the insulator41B, which is located at a radially outward end of the split core4B. The pair of wire engagement portions414similar to those of the first embodiment is formed at an upper end portion of the radially outward flange413B. The high-voltage-side end portion422of the coil42is arranged to extend between the pair of wire engagement portions414. In addition, a support portion (radially outward engagement portion)415B supporting a radially outward side of the resin box43B from a lower side thereof is formed at the radially outward flange413B so as to be arranged between the pair of wire engagement portions414. The support portion415B is positioned further radially inward than the support portion415of the first embodiment, which is shown inFIGS. 8A,8B, and8C. A flat surface (an engagement surface)415Ba is formed at an upper end of the support portion415B so as to face upward.

The resin box43B includes the radially inward terminal-accommodating box431similar to that of the first embodiment. The resin box43B according to the second embodiment includes a pair of protruding walls (radially inward engaged portions)438B and a pair of engagement protruding walls (engagement protruding portions)438Ba instead of the protruding walls438, the engagement protrusions438a, and the leg portions439that are formed at the resin box43in the first embodiment. The pair of protruding walls438B protrudes in parallel to each other and downwardly form the lower ends of the bottom portion435in the circumferential direction. Each of the engagement protruding walls438Ba is formed within a range from an upper end of each of the protruding walls438B and to an intermediate portion in a vertical direction of the protruding wall438B. The engagement protruding wall438Ba has the same wall thickness as the protruding wall438B and protrudes radially inwardly. An upper end of the engagement protruding wall438Ba is integrally formed with the lower end of the bottom portion435in the circumferential direction.

An attaching method to attach the resin box43B to the insulator41B (to attach the radially inward terminal-accommodating box431to the insulator41B) will be described as follows. As illustrated inFIG. 9A, the pair of engagement protruding walls438Ba of the resin box43B is deeply inserted in a movable manner into the pair of engagement grooves412B formed in the radially inward flange411B of the insulator41B, from the radially inward side to the radially outward side and from the upper side to the lower side inFIG. 9Ain a state where the resin box43B is kept inclined.

At this time, a corner portion formed by a radially inward end portion of each of the protruding walls438B and a lower end of each of the engagement protruding walls438Ba is brought into contact with a radially outward edge portion at a lower side of each of the engagement grooves412B; thereby, the resin box43B is restricted from moving radially inwardly relative to the radially inward flange411B and is allowed to move radially outwardly. In addition, a radially inward side of the resin box43B is supported from the lower side thereof by the radially inward flange411B via the corner portion at the engagement protruding wall438Ba. Thus, as indicated by an arrow inFIG. 9A, the resin box43B may be rotated radially from an initial attachment position at the upper side inFIG. 9Ato an attached position located at a lower side of the initial attachment position inFIG. 9Aabout the radially outward edge portion at the lower side of the engagement groove412B in a condition where a radially inward position of the resin box43B is determined as described above. In the midst of the rotation of the resin box43B from the initial attachment position to the attached position as illustrated inFIG. 9A, the extending bottom portion436of the resin box43B does not make contact with the high-voltage-side end portion422that is arranged so as to extend between the wire engagement portions414.

As illustrated inFIG. 9B, when the resin box43B moves downwardly, the inclined surface436bformed at the protruding portion436aof the extending bottom portion436of the resin box43B starts contacting a radially outward edge portion of the flat surface415Ba formed at the support portion415B of the radially outward flange413B. In accordance with the downward rotation of the resin box43B, the inclined surface436bslidably contacts the radially outward edge portion of the flat surface415Ba and is thereafter engaged with the flat surface415Ba. As a result, the resin box43B is guided to move radially outwardly as indicated by an arrow inFIG. 9B.

As illustrated inFIG. 9C, at the radially outward side of the resin box43B, the flat surface415Ba is fully engaged with the inclined surface436bin a state where the resin box43B is completely moved to the attached position relative to the insulator41B. In addition, the extending bottom portion436is supported from the lower side thereof by the flat surface415Ba. Meanwhile, at the radially inward side of the resin box43B, the lower ends of the bottom portion435in the circumferential direction are supported from the lower side thereof by the upper end of the radially inward flange411B. In addition, at the radially inward side of the resin box43B, the pair of engagement protruding walls438Ba is inserted in the pair of engagement grooves412B so as to be shallowly engaged therewith.

According to the second embodiment, in the midst of the rotation of the radially inward terminal-accommodating box431from the initial attachment position to the attached position, the engagement protruding walls438Ba are inserted in and engaged with the engagement grooves412B opened upward. Therefore, the radially inward terminal-accommodating box431is allowed to move upwardly and radially inwardly. Accordingly, in the midst of the attaching operation of the radially inward terminal-accommodating box431relative to the insulator41B or after the radially inward terminal-accommodating box431is completely attached to the insulator41B, the radially inward terminal-accommodating box431may be detached from the radially inward flange411B of the insulator41B. Except for such case, effects of the second embodiment are similar to those of the first embodiment and the description thereof is therefore omitted.

[Third embodiment] A third embodiment of the disclosure will be described as follows with reference toFIGS. 10A,10B, and10C. In the third embodiment, the split core4in the stator1according to the first embodiment is modified to a split core4C corresponding to the core assembly. Other components and the like of the third embodiment are substantially the same as those of the first embodiment, and the description thereof is therefore omitted. In addition, components configuring the split core4C and being the same as the components of the split core4in the stator1of the first embodiment are designated by the same reference numerals and the description thereof is partially omitted.

FIG. 10Aillustrates a state where the resin box43C rotates downwardly from an initial attachment position to an attached position.FIG. 10Billustrates a state where the resin box43C is being guided to move radially outwardly.FIG. 10Cillustrates a state where the resin box43C is completely attached to an insulator41C.

As illustrated inFIG. 100, a radially inward flange (radially inward extending portion)411C extending in a vertical direction of a split core4C and in the circumferential direction of the core unit3, is formed at a portion of the insulator41C, which is located at a radially inward end of the split core4C. A pair of engagement holes (engagement receiving portions, radially inward engagement portions)412C similar to the pair of engagement holes412of the first embodiment is formed at an upper portion of the radially inward flange411C.

A radially outward flange (radially outward extending portion)413C extending in the vertical direction of the split core4C and in the circumferential direction of the core unit3so as to face radially outwardly relative the radially inward flange411C, is formed at a portion of the insulator41C, which is located at a radially outward end of the split core4C. The pair of wire engagement portions414similar to those of the first embodiment is formed at an upper end portion of the radially outward flange413C. The high-voltage-side end portion422of the coil42is arranged to extend between the pair of wire engagement portions414. In addition, a support portion (radially outward engagement portion)415C supporting a radially outward side of the resin box43C from a lower side thereof is formed at the radially outward flange413C so as to be arranged between the pair of wire engagement portions414. The support portion415C is positioned further radially inward than the support portion415of the first embodiment, which is shown inFIGS. 8A,8B, and8C. An inclined surface415Ca similar to the inclined surface415aof the first embodiment is formed at an upper end of the support portion415C.

The resin box43C includes the radially inward terminal-accommodating box431similar to that of the first embodiment. The resin box43C according to the third embodiment includes a bottom portion435C instead of the bottom portion435formed at the resin box43of the first embodiment. The resin box43C further includes a pair of protruding walls (radially inward engaged portions)438C and a pair of engagement protrusions (engagement protruding portions)438Ca instead of the protruding walls438, the engagement protrusions438a, and the leg portions439that are formed at the resin box43in the first embodiment.

A protruding portion436Ca protruding downwardly is formed at a radially outward end portion of an extending bottom portion (radially outward engaged portion)436C of the bottom portion435C. A flat surface (an engagement surface)436Cb is formed at a lower end of the protruding portion436Ca so as to face downward. The pair of protruding walls438C protrudes in parallel to each other and downwardly form lower ends of the bottom portion435C in the circumferential direction. Each of the engagement protrusions438Ca is formed within a range from an upper end of each of the protruding walls438C and to an intermediate portion in a vertical direction of the protruding wall438C. The engagement protrusion438Ca has the same wall thickness as the protruding wall438C. The engagement protrusion438Ca protrudes radially inwardly so as to have a protruding shape that is separated from the bottom portion435C.

An attaching method to attach the resin box43C to the insulator41C (to attach the radially inward terminal-accommodating box431to the insulator41C) will be described as follows. As illustrated inFIG. 10A, the pair of engagement protrusions438Ca of the resin box43C is deeply inserted in a movable manner into the pair of engagement holes412C formed in the radially inward flange411C of the insulator41C, from the radially inward side to the radially outward side and from the upper side to the lower side inFIG. 10Ain a state where the resin box43C is kept inclined.

At this time, a corner portion formed by a radially inward end portion of each of the protruding walls438C and a lower end of each of the engagement protrusions438Ca is brought into contact with a radially outward edge portion at a lower side of each of the engagement holes412C; thereby, the resin box43C is restricted from moving radially inwardly relative to the radially inward flange411C and is allowed to move radially outwardly. In addition, a radially inward side of the resin box43C is supported from the lower side thereof by the radially inward flange411C via the corner portion at the engagement protrusion438Ca. Thus, as indicated by an arrow inFIG. 10A, the resin box43C may be rotated radially from an initial attachment position at the upper side inFIG. 10Ato an attached position located at a lower side of the initial attachment position inFIG. 10Aabout the radially outward edge portion at the lower side of the engagement hole412C in a condition where a radially inward position of the resin box43C is determined as described above. In the midst of the rotation of the resin box43C from the initial attachment position to the attached position as illustrated inFIG. 10A, the extending bottom portion436C of the resin box43C does not make contact with the high-voltage-side end portion422that is arranged so as to extend between the wire engagement portions414.

As illustrated inFIG. 10B, when the resin box43C moves downwardly, a radially inward edge portion of the flat surface436Cb formed at the protruding portion436Ca of the extending bottom portion436C of the resin box43C starts contacting the inclined surface415Ca formed at the support portion415C of the radially outward flange413C. In accordance with the downward rotation of the resin box43C, the flat surface436Cb slidably contacts the radially inward edge portion of the inclined surface415Ca and is thereafter engaged with the inclined surface415Ca. As a result, the resin box43C is guided to move radially outwardly as indicated by an arrow inFIG. 10B.

As illustrated in10C, at the radially outward side of the resin box43C, the inclined surface415Ca is fully engaged with the flat surface436Cb in a state where the resin box43C is completely moved to the attached position relative to the insulator41C. In addition, the extending bottom portion436C is supported from a lower side thereof by the inclined surface415Ca. Meanwhile, at the radially inward side of the resin box43C, the lower ends of the bottom portion435C in the circumferential direction are supported from a lower side thereof by an upper end of the radially inward flange411C. In addition, at the radially inward side of the resin box43C, the pair of engagement protrusions438Ca is inserted in a movable manner into the pair of engagement holes412C so as to be shallowly engaged therewith. Effects of the third embodiment are similar to those of the first embodiment, and the description thereof is therefore omitted.

[Fourth embodiment] A fourth embodiment of the disclosure will be described as follows with reference toFIG. 11. In the fourth embodiment, the split core4in the stator1according to the first embodiment is modified to a split core4D corresponding to the core assembly. Other components and the like of the fourth embodiment are substantially the same as those of the first embodiment, and the description thereof is therefore omitted. In addition, components configuring the split core4D and being the same as the components of the split core4in the stator1of the first embodiment are designated by the same reference numerals and the description thereof is partially omitted.

As illustrated inFIG. 11, the split core4D includes the laminated steel plate40, an insulator41D, the coil42, and the resin box43. Details of the laminated steel plate40, the coil42, and the resin box43according to the fourth embodiment are as explained in the first embodiment. The insulator41D of the fourth embodiment differs from the insulator41of the first embodiment in that a holding protrusion (holding portion)419D is provided.

As illustrated inFIG. 11, the holding protrusion419D is formed at one of the pair of wire engagement portions414of a radially outward flange413D (the radially outward extending portion) of the insulator41D. In the fourth embodiment, the holding protrusion419D is formed at the wire engagement portion414arranged at the side wall433of the resin box43so as to be provided at an inner surface of the wire engagement portion414in the circumferential direction and so as to protrude toward the wire engagement portion414arranged at the side wall434of the resin box43.

Further, the holding protrusion419D is formed so as to have a trapezoidal shape including an inclined surface at an upper side and a flat surface at a lower side when viewed from a radially outward side of the split core4D. The inclined surface is inclined obliquely downwardly in the circumferential direction when viewed from the radially outward side of the split core4D. In a state where the resin box43is attached to the insulator41D as illustrated inFIG. 11, the flat surface at the lower side of the holding protrusion419D is in contact with an upper surface of the extending bottom portion436of the resin box43. The holding protrusion419D partially overlaps the extending bottom portion436when viewed from the upper side inFIG. 11. Therefore, the resin box43is held by the holding protrusion419D so as not to rotate upward from the attached position to the initial attachment position.

In the case of attaching the resin box43to the insulator41D, a lower portion of the extending bottom portion436makes contact with the inclined surface of the holding protrusion419D, which is located at the upper side thereof, in the midst of the rotation of the resin box43from the initial attachment position to the attached position. Each of the resin box43and the insulator41D is formed of a synthetic resin material, and an elastic deformation of the resin box43and the insulator41D is slightly allowed. Accordingly, the resin box43may be moved further downward from a state where the extending bottom portion436is in contact with the holding protrusion419D. In accordance with the rotation of the resin box43, the extending bottom portion436slidably contacts the holding protrusion419D while moving from the upper side to the lower side of the holding protrusion419D; thereafter, the resin box43is moved to the attached position relative to the insulator41D as illustrated inFIG. 11.

According to the fourth embodiment, in a state where the resin box43including the radially inward terminal-accommodating box431to an upper portion of the insulator41D, the radially inward terminal-accommodating box431is held by the holding protrusion419D formed at the radially outward flange413D of the insulator41D, so as not to rotate radially. Therefore, according to the fourth embodiment, the radially inward terminal-accommodating box431is restricted from being detached from the radially outward flange413D. As a result, the radially inward terminal-accommodating box431may be surely held in the attached position. Other effects of the fourth embodiment are similar to those of the first embodiment, and the description thereof is therefore omitted.

[Modified examples of the first, second, and third embodiments] The stator of the rotary electrical machine of the disclosure is not limited to the aforementioned embodiments and may be modified as follows.

For example, in the stator of the rotary electrical machine of the disclosure, the radially inward engaged portion formed at the radially inward terminal-accommodating box may be configured in a different manner from the configuration of the radially inward engaged portion (the protruding wall438,438B,438C) according to the first, second, and third embodiments). In addition, in the stator of the rotary electrical machine of the disclosure, the radially inward engagement portion formed at the radially inward extending portion of the insulator may be configured in a different manner from the configuration of the radially inward engagement portion according to the first, second, and third embodiments (the engagement hole412,412C of the first and third embodiments and the engagement groove412B of the second embodiment). The radially inward engaged portion and the radially inward engagement portion may be configured in various manners as long as the radially inward engaged portion and the radially inward engagement portion are configured to engage each other so as to be a rotation center about which the radially inward terminal-accommodating box431rotates in the radial direction of the core unit3from the initial attachment position to the attached position and so as to move the radially inward terminal-accommodating box431relative to the insulator41,41B,41C in the radial direction. For example, the stator1according to the first embodiment includes pair of protruding walls438and the pair of engagement holes412in the circumferential direction. Alternatively, the stator1may be configured to include the single protruding wall438in the circumferential direction and the single engagement hole412in the circumferential direction.

Further, for example, in the stator of the rotary electrical machine of the disclosure, the radially outward engaged portion formed at the radially inward terminal-accommodating box may be configured in a different manner from the configuration of the radially outward engaged portion according to the first, second, and third embodiments (the extending bottom portion436of the first and second embodiments, the extending bottom portion436C). In addition, in the stator of the rotary electrical machine of the disclosure, the radially outward engagement portion formed at the radially outward extending portion of the insulator may be configured in a different manner from the configuration of the radially outward engagement portion (the support portion415,415B,415C) according to the first, second, and third embodiments. The radially outward engaged portion and the radially outward engagement portion may be configured in various manners as long as the radially outward engagement portion is configured to engage with the radially outward engaged portion in accordance with the rotation of the radially inward terminal-accommodating box and thereby moves the radially inward terminal-accommodating box toward the radially outward terminal-accommodating box in the radial direction. For example, the stator1according to the first embodiment includes the extending bottom portion436serving as the radially outward engaged portion. Alternatively, in the stator1according to the first embodiment, the stepped portions433a,434aformed at the side walls433,434of the radially inward terminal-accommodating box431may be modified to the radially outward engaged portions.

Furthermore, for example, in the first, second, third, and fourth embodiments, the insulating resin material7may be filled in the terminal accommodating box6in a state where one of the connected portion between the neutral point terminal44and the low-voltage-side end portion421of the coil42and the connected portion between the electricity supply terminal54and the high-voltage-side end portion422of the coil42is accommodated in the terminal accommodating box6. In addition, according to the first embodiment, a method to put the insulating resin material7in the terminal accommodating box6is conducted by filling the terminal accommodating box6with the insulating resin material7. Alternatively, a method to put the insulating resin material7in the terminal accommodating box6may be conducted by applying the insulating resin material7to the terminal accommodating box6.

The stator1according to the aforementioned embodiments may be applied to a synchronous motor, an induction motor, a direct current motor, and another rotary electrical machine.

As described above, according to the aforementioned embodiments, the stator1of the rotary electrical machine includes the core unit3configured by the plural split cores4,4B,4C,4D arranged in the annular shape, each of the split cores4,4B,4C,4D including the laminated steel plate40, the insulator41,41B,41C,41D insulating a portion of the laminated steel plate40, and the coil42wound around the insulator41,41B,41C,41D; the bus ring5formed in the annular shape to face the core unit3, the bus ring5supplying an electric power to the coil42; and the radially inward terminal-accommodating box431arranged at the insulator41,41B,41C,41D, accommodating the low-voltage-side end portion421of the coil42, and including the radially inward engaged portions438,438B,438C and the radially outward engaged portion436,436C, the stator1generating a rotating magnetic field when the electric power is applied to the coil42, the insulator41,41B,41C,41D including the radially inward flange411,411B,411C and the radially outward flange413,413B,413C,413D positioned at the radially inward and outward sides of the core unit3relative to the coil42in an extending manner to support the radially inward terminal-accommodating box431, the radially inward flange411,411B,411C including the radially inward engagement portions412,412B,412C which serve as the rotation center about which the radially inward terminal-accommodating box431rotates in the radial direction of the core unit3from the initial attachment position to the attached position and which engage with the radially inward engaged portions438,438B,438C so that the radially inward terminal-accommodating box431is movable relative to the insulator41,41B,41C,41D in the radial direction of the core unit3in a state where the radially inward terminal-accommodating box431is in the attached position, the radially outward flange413,413B,413C,413D including the radially outward engagement portion415,415B,415C which engages with the radially outward engaged portion436,436C in accordance with the rotation of the radially inward terminal-accommodating box431to move the radially inward terminal-accommodating box431in the radial direction.

According to the stator1of the rotary electrical machine according to the aforementioned embodiments, each of the radially inward engaged portions438,438B,438C of the radially inward terminal-accommodating box431is engaged with each of the radially inward engagement portions412,412B,412C of the insulator41,41B,41C,41D; thereafter, the radially inward terminal-accommodating box431is rotated from the initial attachment position to the attached position in a state where the radially inward position of the radially inward terminal-accommodating box431is determined. Therefore, the radially outward engaged portion436,436C of the radially inward terminal-accommodating box431engages with the radially outward engagement portion415,415B,415C of the insulator41,41B,41C,41D in accordance with the rotation of the radially inward terminal-accommodating box431and the radially inward terminal-accommodating box431is therefore guided to move radially toward the radially outward terminal-accommodating box511. As a result, the radially inward terminal-accommodating box431and the radially outward terminal-accommodating box511may be arranged adjacent to one another in a state where the radially inward terminal-accommodating box431is in the attached position.

According to the stator1of the aforementioned embodiments, for example, the insulating resin material7is filled in the terminal accommodating boxes6each formed by the radially outward terminal-accommodating box511and the radially inward terminal-accommodating box431that is rotated to the attached position and that is arranged adjacent to the radially outward terminal-accommodating box511by the engagement of the radially outward engaged portion436,436C with the radially outward engagement portion415,415B,415C. At this time, a clearance from which the insulating resin material7may flow is generated between the radially inward terminal-accommodating box431and the radially outward terminal-accommodating box511until just before the radially inward terminal-accommodating box431is rotated to the attached position. Even in such case, the radially inward terminal-accommodating box431is rotated to the attached position and therefore moves radially toward the radially outward terminal-accommodating box511. As a result, the clearance is reduced. Thus, in the case of attaching the radially inward terminal-accommodating box431to the insulator41,41B,41C,41D, a contact of the radially inward terminal-accommodating box431with the radially outward terminal-accommodating box511is of no concern and the radially inward terminal-accommodating box431may be easily attached to the insulator41,41B,41C,41D. Further, in a state where the radially inward terminal-accommodating box431is attached to the insulator41,41B,41C,41D, the radially inward terminal-accommodating box431and the radially outward terminal-accommodating box511are positioned adjacent to one another. As a result, the insulating resin material7does not flow out from the bottom portion of the terminal accommodating box6and the like at the timing of filling the insulating resin material7in the terminal accommodating boxes6.

Furthermore, as disclosed in the known stator1Z disclosed in Reference2, for example, the attaching operation of the radially inward terminal-accommodating box431Z to the insulator41Z is conducted in a state where the high-voltage-side end portion422of the coil42is positioned to extend between the pair of wire engagement portions414Z. Even in such case, according to the aforementioned embodiments, the radially inward terminal-accommodating box431may be rotated from the initial attachment position to the attached position without concern for a contact of the bottom portion435,435C of the radially inward terminal-accommodating box431with the high-voltage-side end portion422. That is, for example, the low-voltage-side end portion421or the high-voltage-side end portion422of the coil42is arranged at the radially inward terminal-accommodating box431, which is adjacent to a boundary line between the bottom portion435,435C of the radially inward terminal-accommodating box431and the bottom portion of the radially outward terminal-accommodating box511, and the low-voltage-side end portion421or the high-voltage-side end portion422of the coil42is positioned in parallel with the boundary line. Even in such case, according to the configuration of the stator1of the aforementioned embodiments, the radially inward terminal-accommodating box431may be easily attached to the insulator41,41B,41C,41D.

According to the aforementioned embodiments, the inclined surface436band415a,415Ca is formed at one of the radially outward engaged portion436of the radially inward terminal-accommodating box431and the radially outward engagement portion415,415C of the radially outward flange413,413C. The inclined surface436band415a,415Ca is inclined toward the radially inward side as being away from the coil42. The flat surface436Cb,415Ba is formed at the other of the radially outward engaged portion436C of the radially inward terminal-accommodating box431and the radially outward engagement portion415B of the radially outward flange413B. The flat surface436Cb,415Ba slidably contacts the inclined surface415Ca,436bin accordance with the rotation of the radially inward terminal-accommodating box431to the attached position to be engaged with the inclined surface415Ca,436b.

According to the aforementioned configuration, when the radially inward terminal-accommodating box431comes closer to the coil42while rotating to the attached position, the radially outward engaged portion436,436C is guided in a direction of the inclined surface415a,436b,415Ca toward the radially outward side at which the radially inward terminal-accommodating box431is positioned adjacent to the coil42. Thus, according to the stator1of the aforementioned embodiments, in accordance with the rotation of the radially inward terminal-accommodating box431, the radially inward terminal-accommodating box431may be moved radially toward the radially outward terminal-accommodating box511by a simple configuration.

According to the aforementioned embodiments, the bottom portion435,435C of the radially inward terminal-accommodating box431includes the extending bottom portion436,436C arranged at the radially outward side, protruding from the bottom portion435,435C, and forming the radially outward engaged portion436,436C. The radially outward flange413,413B,413C,413D includes the support portion415,415B,415C contacting the extending bottom portion436,436C to support the radially inward terminal-accommodating box431in the attached position. The support portion415,415B,415C forms the radially outward engagement portion415,415B,415C.

According to the aforementioned configuration, the support portion415,415B,415C is brought into contact with the extending bottom portion436,436C; thereby, the radially inward terminal-accommodating box431is supported in the attached position. Thus, two members of the extending bottom portion436,436C and the support portion415,415B,415C may easily or simply establish the engagement between the radially outward engaged portion436,436C and the radially outward engagement portion415,415B,415C and may support the radially outward side of the bottom portion435,435C of the radially inward terminal-accommodating box431.

According to the aforementioned embodiments, the radially inward engaged portion438,438B,438C of the radially inward terminal-accommodating box431includes the protruding wall438,438B,438C protruding from the bottom portion435,435C of the radially inward terminal-accommodating box431toward the coil42and the engagement protruding portion438a,438Ba,438Ca provided at the protruding wall438,438B,438C to protrude therefrom inwardly in the radial direction. The radially inward engagement portion412,412B,412C of the radially inward flange411,411B,411C is configured to be engageable with the engagement protruding portion438a,438Ba,438Ca. The radially inward engagement portion412,412B,412C includes the engagement receiving portion412,412B,412C which supports the radially inward terminal-accommodating box431to be movable in the radial direction by restricting the radially inward terminal-accommodating box431from moving toward the radially inward side relative to the radially inward flange411,411B,411C and by allowing the radially inward terminal-accommodating box431to move toward the radially outward side.

According to the stator1of the aforementioned embodiments, the engagement protruding portion438a,438Ba,438Ca protruding inwardly in the radial direction of the core unit3from the protruding wall438,438B,438C formed at the radially inward terminal-accommodating box431is inserted in and engaged with the engagement receiving portion412,412B,412C included in the radially inward engagement portion412,412B,412C of the radially inward flange411,411B,411C. Therefore, the engagement protruding portion438a,438Ba,438Ca is allowed to move only in the radial direction by the engagement receiving portion412,412B,412C. Here, for example, an end portion of the engagement protruding portion438a,438Ba,438Ca or the protruding wall438,438B,438C is shaped so to be non-insertable in the engagement receiving portion412,412B,412C. In such case, according to the radially inward engaged portion438,438B,438C simply configured as described above and the radially inward engagement portion412,412B,412C simply configured as described above, the radially inward terminal-accommodating box431is restricted from moving radially inwardly relative to the radially inward flange411,411B,411C and is allowed to move radially outwardly from the radially inward flange411,411B,411C. Further, for example, the engagement protruding portion438a,438Ba,438Ca may rotate within the engagement receiving portion412,412B,412C in a state where the radially inward terminal-accommodating box431is restricted from moving radially inwardly relative to the radially inward flange411,411B,411C. In such case, according to the radially inward engaged portion438,438B,438C simply configured as described above and the radially inward engagement portion412,412B,412C simply configured as described above, the radially inward terminal-accommodating box431may rotate in the radial direction.

According to the aforementioned embodiments, the engagement protrusion (the engagement protruding portion)438a,438Ca includes the protruding shape that is separated from the bottom portion435,435C of the radially inward terminal-accommodating box431. The engagement receiving portion412,412C is the engagement hole412,412C which is formed at the radially inward flange411,411C so as to penetrate therethrough and in which the engagement protrusion438a,438Ca is insertable.

According to the aforementioned configuration, the engagement protrusion438a,438Ca is restricted from moving toward the central axis of the core unit3. Therefore, the radially inward terminal-accommodating box431is restricted from loosening from the radially inward flange411,411C. As a result, the radially inward terminal-accommodating box431may be appropriately attached to the insulator41,41C and may be surely held in the attached position.

According to the aforementioned fourth embodiment, the radially outward flange413D includes the holding protrusion419D holding the radially inward terminal-accommodating box431so that the radially inward terminal-accommodating box431is inhibited from rotating in the radial direction toward the initial attachment position in a state where the radially inward terminal-accommodating box431is in the attached position.

According to the aforementioned configuration, the radially inward terminal-accommodating box431is restricted from loosening from the radially outward flange413D, therefore being surely held in the attached position.

According to the aforementioned embodiments, the radially inward terminal-accommodating box431is filled with the insulating resin material7in a state where the low-voltage-side end portion421of the coil42is accommodated in the radially inward terminal-accommodating box431.

According to the stator1of the aforementioned embodiments, the insulating resin material7is filled in each of the terminal accommodating boxes6in a state where one of the connected portion between the neutral point terminal44and the low-voltage-side end portion421of the coil42and the connected portion between the electricity supply terminal54and the high-voltage-side end portion422of the coil42is accommodated in the terminal accommodating box6. Here, as described above, the insulating resin material7does not flow out from the bottom portion of the terminal accommodating box6and the like. As a result, according to the embodiments, the aforementioned connected portions are surely covered by the insulating resin material7and may be therefore insulated.