Patent ID: 12244175

DETAILED DESCRIPTION OF EMBODIMENT(S)

A motor according to the present embodiment will now be described. It should be noted that the present disclosure is not limited to the examples described hereafter, but is intended to include any equivalence to the claims and any modification that is within the scope of the claims.

A motor1may be of an outer rotor type or an inner rotor type. In the present embodiment, the motor1is of the outer rotor type.

The motor1is installed in various types of electric devices and vehicles such as a two-wheel vehicle. For example, the motor1is used as a driving device for a fan of an air blower.

As shown inFIG.1, the motor1is a multiphase motor. The motor1of the present embodiment is a three-phase motor. The motor1includes coil units7of a U-phase, a V-phase, and a W-phase. The coil units7of the U-phase, the V-phase, and the W-phase are stacked in a direction extending along a rotation axis C (hereinafter referred to as “rotation axis direction DC”). The motor1of the present embodiment is of the outer rotor type and includes a claw pole stator.

The motor1includes a stator2and a rotor3. The rotor3is configured to be rotatable about the rotation axis. The rotor3rotates about the rotation axis C. The rotor3is configured so that the stator2is arranged inside the rotor3. The rotor3includes rotor units4, one for each phase. The rotor units4are stacked in the rotation axis direction DC. The rotor units4each include a tubular rotor core5that includes an inner circumferential surface5aextending about the rotation axis C, and magnets6arranged on the inner circumferential surface5aof the rotor core5at predetermined intervals in the circumferential direction. The magnets6are formed by permanent magnets.

As shown inFIG.2, the stator2includes the coil units7. The stator2includes the coil units7, one for each phase. The coil units7are stacked in the axial direction (the direction extending along the rotation axis direction DC) with nonmagnetic bodies arranged therebetween in the rotation axis direction DC. In the present embodiment, the nonmagnetic bodies are formed by spacers8. The coil units7are held by a holding member10.

The coil units7are coupled by the holding member10. In the present embodiment, the coil units7and the spacers8are stacked alternately in the rotation axis direction DC and coupled by the holding member10.

Specifically, a rod13is inserted into core insertion holes42of the coil units7and spacer insertion holes71of the spacers8. In this state, a first member11is attached to one end of the rod13, and a second member12is attached to the other end of the rod13. Then, at least one of the first member11and the second member12is tightened. This sandwiches the coil units7and the spacers8.

Examples of the nonmagnetic bodies include plastic, aluminum, air, and the like. In the present embodiment, the spacers8including nonmagnetic bodies are arranged between the coil units7so that nonmagnetic bodies are present between the coil units7. The spacers8are arranged between the coil units7to restrict magnetic effects between the phases.

A first insulating member may be arranged between the stator2and the first member11of the holding member10. A second insulating member may be arranged between the stator2and the second member12of the holding member10. The holding member10, when formed from a nonmagnetic material, does not need to include the first insulating member or the second insulating member. The holding member10, when formed from a magnetic material, preferably includes the first insulating member and the second insulating member.

The coil units7will now be described with reference toFIGS.3to9.

The coil units7each include a stator core40and a coil20including an annular winding22wound about the rotation axis C. Preferably, the coil unit7includes a bobbin30.

As shown inFIG.3, the bobbin30includes two flanges32and a tubular portion31with a center at the rotation axis C. The tubular portion31includes an insertion hole31athat extends along the rotation axis C. The insertion hole31ais formed to receive a first tubular portion52and a second tubular portion62of the stator core40, which will be described later. The two flanges32are arranged at the ends of the tubular portion31in the rotation axis direction DC.

In the present embodiment, one of the two flanges32of the bobbin30includes a catch33that catches a wire21of the coil20. In one example, the catch33is formed by a notch in the outer edge of the flange32. A through-hole31bextends through the flange32of the tubular portion31near the tubular portion31of the bobbin30. In the present embodiment, the through-hole31bextends through the tubular portion31from an outer circumferential surface31cto an inner circumferential surface31d. The through-hole31bis configured to allow for insertion of the wire21of the coil20through the through-hole31b.

The coil20is formed by the wire21. The wire21includes a conductive core and a coating layer that covers the core. The core is made of metal. In one example, the core is a copper wire. The coating layer is formed by an insulator. In one example, the coating layer is formed by an insulative resin.

As shown inFIG.4, the coil20includes the winding22and two leads (hereafter referred to as first lead23and second lead24) extending from the winding22. The winding22is formed by the wire21wound around the tubular portion31of the bobbin30. The wire21may be wound in any manner. For example, the wire21may be wound around the bobbin30so that the first lead23and the second lead24are both arranged at the outer side of the bobbin30in a radial direction DR. In the present embodiment, the first lead23is arranged at the outer side of the bobbin30in the radial direction DR, and the second lead24is arranged at the inner side of the bobbin30in the radial direction DR. For example, when the second lead24is arranged at the inner side of the bobbin30in the radial direction DR, the wire21is wound around the tubular portion31of the bobbin30so that the first lead23is arranged at the outer side of the bobbin30. The lead layout where the first lead23is arranged at the outer side of the bobbin30in the radial direction DR and the second lead24is arranged at the inner side of the bobbin30in the radial direction DR allows the coil20to be is easily formed through a simple method.

The first lead23is a portion including one end of the wire21, and the second lead24is a portion including the other end of the wire21. The first lead23and the second lead24extend from the coil20to the outer side of the stator2.

The stator core40is formed by a ferromagnet. Examples of a ferromagnet include iron, nickel, cobalt, and a compound including at least one of these substances. The stator core40is configured to hold the bobbins30. The stator core40includes a central portion41, first claw poles55arranged on the outer circumference of the bobbin30at equal intervals, and second claw poles65arranged on the outer circumference of the bobbin30at equal intervals. The central portion41is configured to extend through the insertion hole31aof the tubular portion31of the bobbin30. The central portion41includes the core insertion hole42extending along the rotation axis C. The first claw poles55are continuous with one end of central portion41in the rotation axis direction DC, and the second claw poles65are continuous with the other end of the central portion41in the rotation axis direction DC. When current flows through the coil20, the polarity of the second claw poles65will be opposite to that of the first claw poles55. The central portion41is formed by first cores50, each including a first tubular portion52, and second cores60, each including a second tubular portion62, as will be described below. The stator core40is formed by plural members. An example of the stator core40will now be described.

As shown inFIG.2, the stator core40surrounds at least part of the circumference of the winding22of the corresponding coil20. The stator core40includes projections54,64. The projections54,64are formed on the two ends of the stator core40in the axial direction (direction extending along rotation axis direction DC) and arranged alternately in the circumferential direction. The projections54,64project toward the rotor3in the radial direction DR from the two ends of the stator core40in the axial direction (direction extending along rotation axis direction DC). The stator core40includes the first core50at one side in the axial direction and the second core60at the other side in the axial direction. In the present embodiment, the stator core40includes the first core50and the second core60coupled to the first core50. For example, the first core50and the second core60are formed by powder magnetic cores. Alternatively, the first core50and the second core60may be formed by laminated magnetic cores.

As shown inFIG.5, the first core50includes an annular first ring51, first projections54, and the first claw poles55extending in the axial direction. The first ring51includes the first tubular portion52with a center at the rotation axis C and a first flange53arranged on the outer circumference of the first tubular portion52. The first tubular portion52is configured to be fitted into the insertion hole31aof the tubular portion31of the bobbin30. The first tubular portion52includes a first coupling surface52alocated toward the second core60in the rotation axis direction DC.

The first flange53includes the first projections54arranged at equal intervals in the circumferential direction. In the present embodiment, six first projections54are arranged on the first flange53. The first projections54project from the first flange53in the radial direction DR. The surface facing the bobbin30on the first flange53and the first projections54is flat.

The first claw poles55extend from the distal ends of the first projections54in the rotation axis direction DC (axial direction). The first claw poles55are arranged at equal intervals along a circumference extending about the rotation axis C of the motor1. The first claw poles55face the inner circumferential surface of the rotor3when the rotor3is coupled to the stator2(refer toFIG.1).

As shown inFIG.6, the second core60includes an annular second ring61, second projections64, and the second claw poles65extending in the axial direction. The second ring61includes the second tubular portion62of which center is the rotation axis C and a second flange63arranged on the outer circumference of the second tubular portion62. The second tubular portion62is configured to be fitted into the insertion hole31aof the tubular portion31of the bobbin30. The second tubular portion62includes a second coupling surface62alocated toward the first core50in the rotation axis direction DC. The second coupling surface62acontacts the first coupling surface52a(refer toFIG.9).

The second flange63includes the second projections64arranged at equal intervals in the circumferential direction. In the present embodiment, six first second projections64are arranged on the second flange63. The second projections64project from the second flange63in the radial direction DR. The surface facing the bobbin30on the second flange63and the second projections64is flat.

The second claw poles65extend from the distal ends of the second projections64in the rotation axis direction DC (axial direction). The second claw poles65are arranged between the first claw poles55(refer toFIG.7). Specifically, each second claw pole65is arranged at a position between two first claw poles55in the circumferential direction that extends about the rotation axis C. The second claw poles65face the inner circumferential surface of the rotor3when the rotor3is coupled to the stator2(refer toFIG.1). The first claw poles55and the second claw poles65are arranged alternately in the circumferential direction.

As shown inFIG.9, the second core60is coupled to the first core50so that the second coupling surface62acontacts the first coupling surface52aof the first core50. The second tubular portion62of the second core60is connected to the first tubular portion52of the first core50through crimping, fusing, welding, or bonding. In the present embodiment, the first tubular portion52of the first core50and the second tubular portion62of the second core60are coupled at a coupling portion43. The core insertion hole42of the central portion41is formed when a first insertion hole52bof the first tubular portion52is connected to a second insertion hole62bof the second tubular portion62.

In the present embodiment, the coupling portion43of the first core50and the second core60includes an inter-core gap66between the first core50and the second core60. The inter-core gap66is formed so that at least one of the first lead23and the second lead24is inserted through the inter-core gap66. In the present embodiment, the first tubular portion52of the first core50includes a notch67, through which the second lead24is inserted, as the inter-core gap66.

As shown inFIG.9, the bobbin30is accommodated in the annular space formed by the first core50and the second core60. As described above, the first tubular portion52of the first core50and the second tubular portion62of the second core60are inserted into the insertion hole31aof the bobbin30. The bobbin30is sandwiched by the first flange53of the first core50and the second flange63of the second core60. The catch33of the flange32of the bobbin30is arranged in a first range AR1or a second range AR2(refer toFIG.7).

As shown inFIG.7, the first range AR1is arranged in the stator core40and extends from the first ring51between two adjacent ones of the first projections54. Specifically, as viewed in the rotation axis direction DC, the first range AR1is the area surrounded by the first ring51, two adjacent ones of the first projections54, and the second claw pole65arranged between the two adjacent ones of the first projections54.

The second range AR2is arranged and extends from the second ring61between two adjacent ones of the second projections64. Specifically, as viewed in the rotation axis direction DC, the second range AR2is the area surrounded by the second ring61, two adjacent ones of the second projections64, and the first claw pole55arranged between the two adjacent ones of the second projections64.

Preferably, the catch33of the flange32of the bobbin30is arranged between the second claw pole65and the winding22of the coil20in the first range AR1. Alternatively, the catch33of the flange32of the bobbin30is arranged between the first claw pole55and the winding22of the coil20in the second range AR2.

At least one of the first lead23and the second lead24extends out of the first range AR1or the second range AR2. The at least one of the first lead23and the second lead24further extends between the stator cores40of two coil units7.

Preferably, at least one of the first lead23and the second lead24extends out of the space between the second claw pole65and the coil20in the first range AR1. Alternatively, at least one of the first lead23and the second lead24may extend out of the space between the first claw pole55and the coil20in the second range AR2. The at least one of the first lead23and the second lead24further extends between the stator cores40of two coil units7.

In the present embodiment, the first lead23extends from the outer side of the bobbin30in the radial direction DR. The catch33of the flange32of the bobbin30is arranged between the second claw pole65and the winding22of the coil20in the first range AR1. The first lead23is hooked to the catch33in the flange32of the bobbin30and extended out of the space between the second claw pole65and the coil20in the first range AR1of the first core50.

As shown inFIG.2, the spacers8are arranged between the coil units7as described above. The spacers8include nonmagnetic bodies. Preferably, the spacers8are formed by nonmagnetic bodies. For example, the spacers8are made of resin. The spacers8may include air. The spacers8are flat. The spacers8each include a spacer body70. The spacer body70includes an insertion hole71through which the rod13of the holding member10is inserted.

As shown inFIG.8, the spacer8includes a lead guide72that guides at least one of the first lead23and the second lead24. The lead guide72includes an axial guide portion72aand a radial guide portion72b. The axial guide portion72ais formed in the outer circumferential surface of the spacer body70to extend in the rotation axis direction DC. The radial guide portion72bis formed to be continuous with the axial guide portion72aand arranged in one of the surfaces of the spacer body70to extend from the outer edge to the inner edge of the spacer body70.

Preferably, the spacer8includes at least one of a first engagement portion73(refer toFIG.8), which engages the first lead23, and a second engagement portion78(refer toFIG.24), which engages the second lead24. In the present embodiment, the spacer8includes the first engagement portion73, which engages the first lead23. The first engagement portion73is arranged in the lead guide72. The first engagement portion73includes two protrusions73athat hold the first lead23in between. The two protrusions73aprotrude from the side surfaces of the groove forming the lead guide72.

The layout of the first lead23and the second lead24will now be described with reference toFIG.9. The first claw poles55and the second claw poles65are arranged in one of the inner circumferential portion and the outer circumferential portion of the stator core40, and the first lead23and the second lead24are arranged in the other one of the inner circumferential portion and the outer circumferential portion. In the present embodiment, the first claw poles55and the second claw poles65are arranged in the outer circumferential portion of the stator core40. The first lead23and the second lead24are arranged in the inner circumferential portion of the stator core40. The inner circumferential portion PA of the stator core40is a tubular inner space extending from the inner circumferential surface of the core insertion hole42in the stator core40. The outer circumferential portion of the stator core40is a tubular outer space extending from the outer circumferential surface of the stator core40.

At least one of the first lead23and the second lead24is arranged to extend between the stator cores40of two coil units7. At least one of the first lead23and the second lead24is arranged to extend in the lead guide72of the spacer8. At least one of the first lead23and the second lead24is arranged to extend through the inter-core gap66between the first core50and the second core60. The first lead23and the second lead24are arranged along rod guides14.

In the present embodiment, the first lead23is extended from the outer side of the bobbin30in the radial direction DR, arranged in the lead guide72of the spacer8to extend between the stator cores40, arranged in the inner circumferential portion PA of the stator core40, and arranged along the rod guide14.

The second lead24is arranged at the inner side of the bobbin30in the radial direction DR, inserted through the through-hole31bof the bobbin30and the inter-core gap66of the stator core40, arranged in the inner circumferential portion PA of the stator core40, and arranged along the rod guide14.

As shown inFIGS.10and11, the holding member10includes the first member11, the second member12, and the rod13. The first member11directly or indirectly contacts a first end surface2a, which is one end of the stator2in the rotation axis direction DC. The second member12is configured to directly or indirectly contact a second end surface2b, which is the other end of the stator2that is opposite to the first end surface2ain the rotation axis direction DC.

As shown inFIG.1, the rod13connects the first member11to the second member12. The first member11is coupled to a first end13aof the rod13. The second member12is coupled to a second end13bof the rod13that is opposite to the first end13a. At least one of the first member11and the second member12is connected to the rod13. In the present embodiment, the second member12is coupled to the rod13with a screw structure. The first member11is formed integrally with the rod13.

The rod13is configured to extend through the coil units7. Specifically, the rod13is configured to be inserted through the core insertion holes42of the stator cores40. The rod13has an outer circumference that includes the rod guides14. The rod guides14each extend from the vicinity of the first end13ato the second end13bin the longitudinal direction of the rod13. The rod guide14is recessed from the outer circumferential surface of the rod13to receive at least one of the first lead23and the second lead24. In the present embodiment, the outer circumferential surface of the rod13includes six rod guides14. The rod guides14each accommodate one of the first lead23and the second lead24of the phases.

A method for manufacturing the motor1will now be described with reference toFIG.12.

In this example, the first member11is formed integrally with the rod13. The coil units7are assembled in advance. The first leads23and the second leads24extend from the coils20of the coil units7. The coil units7are fitted onto the rod13so that the rod13extends through the core insertion holes42with the first leads23and the second leads24arranged in separate rod guides14. The motor1is assembled through the following procedures. The coil unit7of a first phase (for example, U-phase) is fitted onto the rod13, then the spacer8is fitted onto the rod13, and then the coil unit7of a second phase (for example, V-phase) is fitted onto the rod13. Then, the spacer8is fitted onto the rod13, and the coil unit7of a third phase (for example, W-phase) is fitted onto the rod13. Then, the second member12is fastened to the second end13bof the rod13. The second member12is tightened so that the three coil units7and the two spacers8are held by the holding member10.

The operation of the present embodiment will now be described.

The first claw poles55and the second claw poles65are arranged in one of the inner circumferential portion PA and the outer circumferential portion of the stator core40. If at least one of the first lead23and the second lead24were to be arranged in the same portion of the stator core40where the first claw poles55and the second claw poles65are arranged, at least one of the first lead23and the second lead24would be arranged in an air gap between the stator2and the rotor3. In this case, the at least one of the first lead23and the second lead24may contact the rotor3. In the present embodiment, the first lead23and the second lead24are not laid out in or near the air gap between the rotor3and the stator2. Alternatively, the first lead23and the second lead24are laid out so that the portions in or near the air gap between the rotor3and the stator2are reduced in length. This limits contact of the first lead23and the second lead24with the rotor3.

The present embodiment has the following advantages.

(1) In the motor1, at least one of the first lead23and the second lead24of the coil20is arranged to extend between the stator cores40of two coil units7. Further, the first claw poles55and the second claw poles65are arranged in one of the inner circumferential portion PA and the outer circumferential portion of the stator core40, and the first lead23and the second lead24are arranged in the other one of the inner circumferential portion and the outer circumferential portion.

With this structure, the first lead23and the second lead24are not arranged in the air gap between the rotor3and the stator2so that contact of the first lead23and the second lead24with the rotor3is limited.

(2) The spacers8including nonmagnetic bodies are arranged between the coil units7. At least one of the first lead23and the second lead24is arranged to extend in the lead guide72of the spacer8. This structure limits displacement of the lead between the coil units7.

(3) The spacer8includes at least one of the first engagement portion73, which engages the first lead23, and the second engagement portion78, which engages the second lead24. This structure restricts movement of at least one of the first lead23and the second lead24when the motor1vibrates. In other words, the structure restricts wear of at least one of the first lead23and the second lead24when vibration of the motor1vibrates the leads.

(4) At least one of the first lead23and the second lead24is extended out of the first range AR1or the second range AR2and arranged to extend through the space between the stator cores40of the two coil units7. This structure allows the at least one of the first lead23and the second lead24to be easily laid out.

(5) At least one of the first lead23and the second lead24is extended out of the space between the second claw pole65and the coil20in the first range AR1. Alternatively, at least one of the first lead23and the second lead24is extended out of the space between the first claw pole55and the coil20in the second range AR2. Further, the at least one of the first lead23and the second lead24is extended between the stator cores40of two coil units7. With this structure, at least one of the first lead23and the second lead24is sandwiched between the first claw pole55and the coil20or between the second claw pole65and the coil20. This avoids movement of the at least one of the first lead23and the second lead24into the air gap between the rotor3and the stator2.

(6) At least one of the first lead23and the second lead24extends through the inter-core gap66between the first core50and the second core60at the coupling portion43of the first core50and the second core60.

If a hole were to be formed in the first core50or the second core60, the insertion of the second lead24through the hole would take time. In this respect, the above structure sets the arrangement of at least one of the first lead23and the second lead24when the first core50and the second core60are coupled during the manufacturing of the motor1. This improves the production efficiency of the motor1.

(7) The first lead23and the second lead24are arranged along the rod guides14of the holding member10. This structure restricts movement of the first lead23and the second lead24when the motor1vibrates.

(8) The motor1further includes the bobbin30. The winding22of the coil20is formed by winding the wire21around the tubular portion31of the bobbin30. The stator core40holds the bobbin30. With this structure, the coil20is positioned relative to the stator core40through a simple assembling process.

Modifications

Modifications of the motor1of the above embodiment will now be described below. In the description of modifications, the same reference numerals are given to configurations that are the same as those of the embodiment to facilitate the description, and such configurations are not described. The motor1in the modifications described below has substantially the same advantages as the motor1of the embodiment.

First Modification

The bobbin30according to a modification will now be described with reference toFIGS.13and14. In this example, the first lead23extends out of the bobbin30from a portion that differs from that of the first embodiment. In the first embodiment, the catch33of the bobbin30is formed by a notch near the outer edge of the flange32. In this example, the catch33of the bobbin30is formed by a slit34that extends in the radial direction DR. The width of the slit34is set to allow the first lead23to pass through the slit34. The first lead23extends out of the bobbin30from near the tubular portion31. In this case, the spacer8includes a slit (refer to spacer slit75ofFIG.21). The first lead23extends through the slit34of the bobbin30, the first range AR1of the first core50, and the slit of the spacer8, and is guided to the rod guide14of the rod13of the holding member10. In this example, the portion of the first lead23that extends through the slit of the spacer8is arranged between the stator cores40. In the bobbin30of the first embodiment, the through-hole31bthrough which the second lead24extends may be replaced by the slit34.

Second Modification

The bobbin30according to another modification will now be described with reference toFIG.15. In the first embodiment, the catch33of the bobbin30is formed by a notch near the outer edge of the flange32. In this example, the catch33of the bobbin30is formed by a through-hole35in the flange32near the tubular portion31. In this case, the spacer8includes a slit (refer to spacer slit75ofFIG.21). The first lead23extends through the through-hole35of the bobbin30, the first range AR1of the first core50, and the slit of the spacer8, and is guided to the rod guide14of the rod13of the holding member10. In the bobbin30of the first embodiment, the through-hole31bthrough which the second lead24extends may be replaced by the through-hole35of the modification.

Third Modification

The first core50according to another modification will now be described with reference toFIGS.16and17. The coil unit7shown inFIGS.16and17includes the bobbin30of the second modification. In the first core50of the third modification, the first flange53includes a core catch56. The core catch56is formed by a recess, which engages the first lead23. The core catch56is arranged in the first range AR1of the first core50. The first lead23hooked to the core catch56. This restricts movement of the first lead23when the motor1vibrates.

Fourth Modification

The bobbin30according to another modification will now be described with reference toFIGS.18and19. The catch33of the bobbin30may be arranged in a groove36. The groove36is arranged in the one of the two flanges32that is closer to the first core50and in the surface of that flange that is closer to the coil20. Preferably, the thickness of the flange32that includes the groove36is greater than the thickness of the flange32that does not include the groove36. The width of the groove36is set to allow the first lead23to pass through the groove36.

Fifth Modification

The spacer8according to another modification will now be described with reference toFIGS.20and21. The spacer8includes the spacer slit75extending in the radial direction DR. The width of the spacer slit75is set to allow the first lead23to pass through the spacer slit75. Preferably, the spacer slit75includes the first engagement portion73, which engages the first lead23in the same manner as in the embodiment. The first engagement portion73is formed by two protrusions73b. In the rotation axis direction DC, the distal ends of the two protrusions73bare joined in part and separated in part. The partial coupling of the two protrusions73bmaintains the shape of the spacer slit75. The first lead23is held between the separated portions of the two protrusions73b.

Sixth Modification

The spacer8according to another modification will now be described with reference toFIGS.22and23. In this example, the spacer8is not fitted onto the rod13of the holding member10. The spacer8is supported and held between the coil units7. A spacer body77is ring-shaped and has an inner diameter that is greater than the diameter of the rod13. Preferably, the inner diameter of the spacer body77is substantially the same as the diameter of the bobbin30. When the motor1is assembled, the spacer8forms an air layer77a(nonmagnetic body layer) between the coil units7. The first lead23extends through the spacer body77. In this manner, the spacer8is not limited to the shape illustrated in the embodiment. The spacer8may be rectangular or triangular.

Seventh Modification

The spacer8according to another modification will now be described with reference toFIGS.24and25. In this example, the spacer8includes the second engagement portion78that engages the second lead24. The second engagement portion78is arranged on the inner circumferential surface of the insertion hole71of the spacer8. The second engagement portion78is formed to be two flaps78athat hold the second lead24. The second lead24is held by the second engagement portion78. This structure restricts movement of the second lead24when the motor1vibrates.

Eighth Modification

The stator core40according to another modification will now be described with reference toFIG.26. The first ring51of the first core50includes a connection ring (not shown) that connects the six first projections54and three first fitting portions91arranged in the inner circumferential portion of the connection ring. The first fitting portions91extend in the rotation axis direction DC. The second ring61of the second core60, which has the same structure as the first ring51of the first core50, includes a connection ring92and second fitting portions93. The second fitting portions93of the second core60are fitted between the first fitting portions91of the first core50to couple the second core60to the first core50. Such a fitting structure joins the first core50and the second core60.

The inter-core gap66is formed between the first fitting portion91and the second fitting portion93. In the present embodiment, the inter-core gap66is formed by a cutout94in the first fitting portion91. Alternatively, the second fitting portion93may include the cutout94. The cutout94is formed so that the second lead24extends through the cutout94. This structure allows the second lead24to be arranged when the first core50and the second core60are coupled during the manufacturing of the motor1so that the production efficiency of the motor1is improved.

Ninth Modification

Preferably, a portion of at least one of the first lead23and the second lead24that contacts the stator core40is surrounded by an insulating member98. Examples are described in a ninth modification and a tenth modification.

The bobbin30and the stator core40according to another modification will now be described with reference toFIGS.27to29.FIG.29is a diagram showing a view taken in arrow A inFIG.28. As shown inFIG.27, the tubular portion31of the bobbin30includes a projection95. The projection95projects from the inner circumferential surface of the tubular portion31in the radial direction DR. The projection95includes a through-hole96through which the second lead24is inserted. The projection95is made of an insulating resin. As shown inFIGS.28and29, the first core50includes a notch97into which the projection95is inserted. In this manner, the portion of the second lead24that contacts the stator core40is surrounded by the insulating member98. This structure obtains a creepage distance between the second lead24and the stator core40and improves insulation.

Tenth Modification

The bobbin30and the stator core40according to another modification will now be described with reference toFIGS.30to32.FIG.32is a diagram showing a view taken in arrow B inFIG.30. As shown inFIG.30, the tubular portion31of the bobbin30includes a tube through-hole101through which a tube102extends. The tube102is made of an insulating resin. The tube through-hole101extends through the tubular portion31in the radial direction DR. The tube102is arranged in the tube through-hole101. The second lead24is inserted through the tube102. As shown inFIGS.31and32, the first core50includes a tube notch103into which the tube102is inserted. In this manner, the portion of the second lead24that contacts the stator core40is surrounded by the insulating member98. This structure obtains the creepage distance between the second lead24and the stator core40and improves insulation.

As shown inFIG.33, a tube104may be formed to have a cross-sectional area that increases from a first end to a second end. The cross-sectional area indicates the area of a cross-section that intersects a line extending in the through-hole of the tube104. The first end is arranged at the inner circumferential surface side of the tubular portion31of the bobbin30, and the second end is arranged at the outer circumferential surface side of the tubular portion31of the bobbin30. In this case, the tube104is preferably flexible. Such a tube104reduces contact between the second lead24and the first core50as compared with the tube104. The tube104also obtains a creepage distance.

Eleventh Modification

The bobbin30according to another modification will now be described with reference toFIGS.34to36. In this example, the bobbin30includes a positioning portion110. As shown inFIG.35, the positioning portion110includes first steps111and second steps112that are engaged with the stator core40. The first steps111and the second steps112are arranged on the outer surfaces of the flanges32. The first steps111of the flange32arranged toward the first core50are each formed to contact two of the first projections54and the first flange53of the first core50. The two first steps111of the flange32arranged toward the first core50are located at symmetrical positions with respect to the rotation axis C. The second steps112of the flange32arranged toward the second core60are each formed to contact two of the second projections64and the second flange63of the second core60. The two second steps112of the flange32arranged toward the second core60are located at symmetrical positions with respect to the rotation axis C. With this structure, the bobbin30is easily positioned relative to the stator core40.

Twelfth Modification

The bobbin30according to another modification will now be described with reference toFIGS.37and38. In this example, the bobbin30includes the positioning portion110. The positioning portion110includes steps113engaged with the stator core40. The steps113are arranged on at least one of the two flanges32of the bobbin30. The steps113project from the outer edge of the flange32in the radial direction DR. In the present embodiment, the steps113are each arranged between the first claw pole55and the second claw pole65on the flange32that is in contact with the first core50so that the steps113contact the two magnetic poles. With this structure, the bobbin30is easily positioned relative to the stator core40.

Thirteenth Modification

The holding member10according to another modification will now be described with reference toFIG.39.FIG.39is a plan view of the member formed by coupling the first member11to the rod13. In this example, the rod13of the holding member10includes a first guide121and a second guide122as the rod guides14. The first guide121is formed so that three first leads23are inserted through the first guide121. The second guide122is formed so that three second leads24are inserted through the second guide122. This structure simplifies the structure of the rod13.

Fourteenth Modification

The holding member10according to another modification will now be described with reference toFIGS.40and41.FIG.40is a plan view of the member formed by coupling the first member11to the rod13. In this example, the rod13of the holding member10includes a lead accommodating portion123as the rod guide14. The lead accommodating portion123is formed so that three first leads23and three second leads24are inserted through the lead accommodating portion123. The lead accommodating portion123is formed to be space extending in rotation axis C inside the rod13. The rod13has side surfaces that include slits124connected to the lead accommodating portion123(refer toFIG.41).

Fifteenth Modification

The spacer8according to another modification will now be described with reference toFIGS.42and44. The spacer8includes at least one of a first bending guide131and a second bending guide132. The first bending guide131gradually bends the first lead23. Specifically, the first bending guide131guides the first lead23without breaking the first lead23. The second bending guide132gradually bends the second lead24. Specifically, the second bending guide132guides the second lead24without breaking the second lead24.

As shown inFIGS.42and43, the first bending guide131includes a first guide body131aand a first guide groove131barranged in the first guide body131a. The first guide body131ais arranged at a portion where the inner circumferential surface of the insertion hole71intersects the lead guide72. The first guide body131aextends in the direction (hereafter lead guide direction) that guides the first lead23in the rotation axis C. The lead guide direction in the present embodiment extends toward the second member12(refer toFIG.1). The first guide groove131bis formed in the first guide body131ato be continuous with the lead guide72. As the first guide groove131bextends toward the rotation axis C, the first guide groove131bis gradually curved and extends in the lead guide direction.

As shown inFIGS.42and44, the second bending guide132includes a second guide body132aand a second guide groove132barranged in the second guide body132a. The second guide body132ais arranged in the insertion hole71where the second lead24extends. The second guide body132aextends to the vicinity of the notch67(inter-core gap66) of the first core50along the inner circumferential surface of the first tubular portion52of the first core50where the second lead24extends. The second guide groove132bis formed in the second guide body132ato be continuous with the notch67of the first core50. As the second guide groove132bbecomes closer to the rotation axis C, the second guide groove132bis gradually curved and extends in the lead guide direction. This structure gradually bends at least one of the first lead23and the second lead24and reduces breaking of the at least one of the first lead23and the second lead24.

Other Modifications

The motor1of the present disclosure may be modified as follows in addition to the above embodiment and modifications or have a mode in which at least two modifications are combined as long as the modifications are consistent with each other.

In the present embodiment and the modifications, the motor1is of an outer rotor type and includes a claw pole stator. Alternatively, the technique of the present disclosure can be applied to a stator of a motor of an inner rotor type. In the technique of the present disclosure, magnetic poles are arranged in one of the inner circumferential portion and the outer circumferential portion of the stator core40, and the first lead23and the second lead24are arranged in the other one of the inner circumferential portion and the outer circumferential portion. In contrast, in the stator of the motor of the inner rotor type, the first lead23and the second lead24are arranged in the outer circumferential portion of the stator.

Although the motor1according to the embodiment has been described above, it will be understood that various changes in modes and details can be made without departing from the spirit and scope of the motor1in the claims.