DESCRIPTION OF PREFERRED EMBODIMENTS

[0071] Embodiment 1.

[0072] In the following, the first embodiment of the present invention will be explained by referring to the figures.

[0073] FIGS. 1 and 2 show the first embodiment. FIG. 1 is a plan view of a stator of an electric motor, and FIG. 2 is a plan view showing a part of the electric motor and explaining how to wind a coil wire of the stator of the electric motor.

[0074] In FIG. 1, a reference numeral 1 shows a plate-shaped core segment (magnetic pole segment) made of magnetic material, and a reference numeral 9 shows a connection portion (also called as a joint portion) consisting of a concave portion 3 a and a convex portion 3 b provided to both surfaces of one end of the magnetic pole segment 3 as a connection means. 4 shows the first iron core member in which plural magnetic pole segments 3 are aligned via an end face 3 c and an end face 3 d of each segment.

[0075] A reference numeral 5 shows the second iron core member in which plural magnetic pole segments 3 are aligned, and the second iron core member and the first iron core member are stacked or laminated alternately. The concave portion 3 a of a certain magnetic pole segment 3 is engaged with the convex portion 3 b of an adjoining magnetic pole segment so that the magnetic pole segments 3 are connected so as to turn freely around a center of the concave portion 3 a and the convex portion 3 b . A reference numeral 7 shows an iron core which is circularly formed by turning the concave portion 3 a and the convex portion 3 b of the connection portion 9 of each magnetic pole segment 3 made by laminating both iron core members.

[0076] A reference numeral 3 e shows a back yoke portion of the magnetic pole segment 3 , and 3 f shows a teeth portion.

[0077] 2 shows a slot formed by the back yoke portion 3 e and the teeth portion 3 f , and 2 a shows a bottom portion of the slot. The bottom portion 2 a of the slot is constituted by the back yoke portions 3 e of the first iron core member 4 and the second iron core member 5 . The bottom portion 2 a has a curved line and does not have a fine angle.

[0078] A reference numeral 8 shows an insulator member coated on the teeth portion 3 f to cover a wall of the teeth portion 3 f . The insulator member wall of the back yoke portion makes around 90° with the insulator member wall of the teeth portion 3 f , and further the insulator member 8 covers a projected portion 3 g of the back yoke portion 3 e.

[0079] A coil wire is wound in the slot 2 in this embodiment, however, the coil wire is not illustrated in FIG. 1 for clarifying the explanation. An illustration of the insulator member 8 is partially omitted, too.

[0080] The connection portion 9 is provided at an outer circumference side of the back yoke portion 3 e . At around the connection portion 9 , the end faces 3 c and 3 d form a male shape 3 i and a female shape 3 j , each having a half circular shape with a center of the connection portion 9 . On the other side, a straight line portion 3 k and a straight line portion 3 l are formed from around the connection portion 9 toward the projected portion 3 g . Further, by providing the projected portion 3 g as shown in FIG. 1 , it becomes possible to make a length L 1 of the end portion of the back yoke portion 3 e in the radius direction equal to a length L 2 of the center portion of the back yoke portion 3 e in the radius direction. Another structure can be made in which a length L of the back yoke portion 3 e in the radius direction has the same size at any portion (L=L 1 =L 2 ) and the curved line of the bottom portion 2 a of the slot is made to be an arc of a circle having a center which is a center W of a rotation axis of the rotor.

[0081] The stator is structured as described above, the bottom portion 2 b of the slot forms the curved line, so that the stress of the load is distributed to the straight line portions 3 k and 3 l formed from around the connection portion 9 toward the projected portion 3 g , and is not concentrated to the bottom portion 2 a of the slot at the time of forming the iron core 7 circularly or at the time of fixing the stator of the electric motor in the housing and the like by press-fitting or shrink-fitting. Therefore, the magnetic performance is not lost, and further problems can be eliminated that the efficiency of the electric motor becomes worse, sufficient stiffness cannot be kept, or vibration or noise is generated on driving the electric motor.

[0082] Further, when the bottom portion 2 a of the slot is formed by the curved line, the portion 3 g is projected. The coil wire 6 is wound so that a nozzle keeps parallel to the teeth portion 3 f as shown in FIG. 2 . At this time, the projected portion 3 g may injure the coil wire on winding the coil wire 6 , and further, an undesirable space, in which the coil wire cannot be wound to avoid injuring the coil wire, may be generated at the back yoke portion 3 e side. However, since the insulator member 8 is coated on the teeth portion 3 f to cover the projected portion 3 g , the coil wire 6 can be wound without the undesirable space and without being injured.

[0083] Embodiment 2.

[0084] In the following, the second embodiment of the present invention will be explained referring to the figures.

[0085] FIG. 3 shows a plan view of the stator of the electric motor according to the second embodiment. In FIG. 3, a reference numeral 3 shows a plate-shaped core segment (magnetic pole segment) made of the magnetic material. A reference numeral 9 shows a connection portion constituted by a concave portion 3 a and a convex portion 3 b provided to both surfaces of one end of the magnetic pole segment 3 as a connection means. 4 shows the first iron core member in which plural magnetic pole segments 3 are aligned via an end face 3 c and an end face 3 d of each segment.

[0086] A reference numeral 5 shows the second iron core member in which plural magnetic pole segments 3 are aligned, and the second iron core member and the first iron core member are stacked or laminated alternately. The concave portion 3 a of a certain magnetic pole segment 3 is engaged with the convex portion 3 b of an adjoining magnetic pole segment so that the magnetic pole segments 3 are connected so as to turn freely around a center of the concave portion 3 a and the convex portion 3 b . A reference numeral 7 shows an iron core which is circularly formed by turning the concave portion 3 a and the convex portion 3 b of the connection portion 9 of each magnetic pole segment 3 made by laminating both iron core members.

[0087] A reference numeral 3 e shows a back yoke portion of the magnetic pole segment 3 , and 3 f shows a teeth portion. 10 shows a notch formed at a place opposite to the connection portion 9 and extended to the direction of rotation axis of the rotor. A coil wire is wound in the slot 2 in this embodiment, however, the coil wire is not illustrated in FIG. 3 for clarifying the explanation.

[0088] When the stator of the electric motor is fixed in the housing and the like by press-fitting or shrink-fitting, since the notch is formed at the place opposite to the connection portion 9 and extended to the direction of rotation axis of the stator, the stator of the electric motor is not directly pressed against the housing around the connection portion 9 . Accordingly, the notch 10 with an appropriate size can adjust the load applied to the connection portion 9 when the stator of the electric motor is inserted in the housing and the like by press-fitting or shrink-fitting.

[0089] Consequently, it is possible to minimize the stress applied to the connection portion 9 with keeping the sufficient stiffness by selecting an appropriate length U of the notch 10 in the circumference direction.

[0090] Further, the insulator film covering the magnetic material is removed from the connection portion 9 on forming the iron core 7 , the concave portion 3 a or the convex portion 3 b . Accordingly, the insulation resistance is lowered between iron core members 4 and 5 , eddy current is generated on driving the electric motor, and further, the efficiency of the motor is reduced.

[0091] The above problem can be also solved by the present embodiment. By changing the length U of the notch 10 in the circumference direction, the contact power between the inside of the housing and the outer circumference of the stator of the electric motor can be minimized while keeping a required contact power. By minimizing the contact power, the insulation resistance of each of the iron core members 4 and 5 in the direction of rotation axis is not lowered or increased. Therefore, it becomes possible to minimize the reduction of the efficiency of the electric motor caused by the eddy current generated in the iron core 7 . Therefore, sufficient stiffness of the stator can be kept without losing the magnetic performance of the magnetic material or reducing the efficiency of the electric motor caused by the eddy current.

[0092] Embodiment 3.

[0093] In the following, the third embodiment of the present invention will be explained referring to the figures.

[0094] FIG. 4 shows a plan view of the stator of the electric motor according to the third embodiment. In FIG. 4, a reference numeral 3 shows a plate magnetic pole segment made of the magnetic material. A reference numeral 9 shows a connection portion constituted by a concave portion 3 a and a convex portion 3 b provided to both sides of one end of the magnetic pole segment 3 as a connection means. 4 shows the first iron core member in which plural magnetic pole segments 3 are aligned via an end face 3 c and an end face 3 d of each segment.

[0095] A reference numeral 5 shows the second iron core member in which plural magnetic pole segments 3 are aligned, and the second iron core member and the first iron core member are stacked or laminated alternately. The concave portion 3 a of a certain magnetic pole segment 3 is engaged with the convex portion 3 b of an adjoining magnetic pole segment so that the magnetic pole segments 3 are connected so as to turn freely around a center of the concave portion 3 a and the convex portion 3 b . A reference numeral 7 shows an iron core which is circularly formed by turning the concave portion 3 a and the convex portion 3 b of the connection portion 9 of each magnetic pole segment 3 made by laminating both iron core members.

[0096] A reference numeral 3 e shows a back yoke portion of the segment 3 , and 3 f shows a teeth portion. 11 shows a notch formed at a place opposite to the teeth portion 3 f and extended to the direction of rotation axis of the rotor.

[0097] A coil wire is substantially wound in the slot 2 in this embodiment, however, the coil wire is not illustrated in FIG. 4 for clarifying the explanation.

[0098] When the stator of the electric motor is inserted in the housing and the like by press-fitting or shrink-fitting, since the contact area can be changed by changing a length T of the notch in the circumference direction, it becomes possible to minimize the stress of compression applied to the stator of the electric motor with the sufficient fixing force.

[0099] Further, the notch 11 is located at the place opposite to the teeth portion 3 f , and the magnetic flux of the place of the notch is lower compared with other portion of the iron core on driving the electric motor. Therefore, providing the notch at this place causes the reduction of the efficiency of the electric motor less than a case in which the notch is provided at other place of the iron core.

[0100] Embodiment 4.

[0101] In the following, the fourth embodiment of the present invention will be explained referring to the figures.

[0102] FIGS. 5 and 6 show the fourth embodiment. FIG. 5 shows a plan view of a band-shaped stator of the electric motor, and FIG. 6 shows a plan view of a stator of the electric motor formed circularly.

[0103] In FIG. 5, a reference numeral 21 shows a plate-shaped magnetic pole segment (also called as a core segment), and a reference numeral 22 shows a thin connection portion provided to the magnetic pole segment 21 . 21 a shows a teeth portion of the magnetic pole segment 21 , and 22 a and 22 b show confronting surfaces of the connection portion located at both sides of the thin connection portion 22 . 21 b and 21 c show V-shaped confronting surfaces of end portions, each of which is located at an opposite side to the thin connection portion 2 of the magnetic pole segment 21 placed at far end.

[0104] A method for manufacturing the stator of the electric motor structured as described above will be explained hereinafter. After the coil wire (not illustrated) is wound around the teeth portion 21 a , the thin connection portion 22 of each magnetic pole segment 21 is bent, the confronting surfaces 22 a and 22 b of the connection portion are faced so that the location of each magnetic pole segment 21 is determined. Finally, the confronting surfaces 21 b and 21 c of the end portions of the both ends are faced to make a circular form, the form is fixed by welding, etc., and a terminal wire of the coil wire is electrically connected to make the stator of the electric motor.

[0105] As the stator is structured as described above, the relationship of the location of each magnetic pole segment 21 should be determined by each of the confronting surfaces 22 a and 22 b of the connection portions and the confronting surfaces 21 b and 21 c of the end portions. Since the confronting surfaces 21 b and 21 c of the end portions have V-shapes of male shape and female shape, the movement of the stator in the radius direction will be restricted when the V-shape of male shape and the V-shape of female shape are faced. Accordingly, the mechanical precision of the stator of the electric motor will be directly determined. It is possible to easily secure the mechanical precision by improving the precision of punching the magnetic pole segment 21 and so on.

[0106] In the present embodiment, the connection portion is made thin, however, the same effect can be brought when the embodiment is applied to a case in which a connection portion is made by one of other ways and the stator is circularly formed from the aligned plural magnetic pole segments 21 .

[0107] Embodiment 5.

[0108] In the following, the fifth embodiment of the present invention will be explained referring to the figures.

[0109] FIG. 7 shows the fifth embodiment and is a plan view of the stator of the electric motor just before formed circularly.

[0110] In FIG. 7, a reference numeral 21 shows a plate-shaped magnetic pole segment made of magnetic material, and a reference numeral 22 shows a thin connection portion provided to the magnetic pole segment 21 . 22 a and 22 b show confronting surfaces of the connection portions located at both sides of the thin connection portion 22 . 21 b and 21 c show V-shaped confronting surfaces of end portions, each of which is located at opposite side to the thin connection portion 2 of the magnetic pole segment 21 placed at far end.

[0111] The confronting surfaces 21 b and 21 c of the end portions are constituted by two arc shapes, the first arc 21 d and the second arc 21 e . Centers of the arcs are approximately the same to turning centers S 1 and S 2 which are turning points for bending the thin connection portions of any two of the magnetic pole segments 21 .

[0112] The stator is structured as described above, turning centers S 1 and S 2 of the thin connection portions of specific magnetic pole segments 21 are centers of the first arc 1 d and the second arc 1 e , respectively, and turning centers S 1 and S 2 are turning points when the both far ends of magnetic pole segment are finally to be faced. Therefore, when the thin connection portion 22 of the specific magnetic pole segment is bent at last, the magnetic pole segments 21 are not disturbed each other, and the stator can be formed circularly out of plural magnetic pole segments.

[0113] Accordingly, it is no need to determine an order of bending magnetic pole segments at bending process, and manufacturing the stator can be performed more flexibly in the aspect of facilities. Further, since the disturbance at bending process can be eliminated, the high reliability can be obtained in manufacturing the stator of the electric motor.

[0114] In the above embodiment, the connection portion is made thin. However, the same effect can be obtained by making the connection portion in one of other ways and the stator is circularly formed from the aligned plural magnetic pole segments 21 .

[0115] Embodiment 6.

[0116] In the following, the sixth embodiment of the present invention will be explained referring to the figures.

[0117] FIG. 8 shows a plan view of a part of the stator of the electric motor according to the sixth embodiment.

[0118] In FIG. 8, a reference numeral 21 shows a plate-shaped magnetic pole segment made of magnetic material, and 21 b and 21 c show V-shaped confronting surfaces of end portions, each of which is located at the opposite side to a thin connection portion 22 of the magnetic pole segment 21 placed at far end. 23 shows a jut, which is formed on facing the confronting surfaces of the end portions, jutted out to an outer circumference of the stator. The jut 23 is located inside of the outer circumference of the stator of the electric motor.

[0119] The stator is structured as described above, on finally joining both ends of magnetic pole segments, top point of the jut 23 face to the outer circumference. Accordingly, when the confronting surfaces 21 b and 21 c of the end portions are joined, it is possible to easily blow an electric arc to the top point of the jut 23 , which requires to be welded, and possible to weld the confronting surfaces more sufficiently compared with welding to a flat plane or an arc plane of the outer circumference.

[0120] Embodiment 7.

[0121] An embodiment for the electric motor and the compressor will be explained in the following.

[0122] FIG. 9 shows a plan view of an electric motor employing the stator iron core of the electric motor according to the first through fourth embodiments.

[0123] After the coil wire 6 is wound around the insulator member 8 on the teeth portion 3 f of the stator iron core 7 of the electric motor, appropriate electric wire connections are made, the rotor 12 having the rotation axis 13 is inserted into the stator. Accordingly, the electric motor 14 is formed.

[0124] The application of the present invention is not limited to a case employing the stator iron core according to the first through fourth embodiments, but the invention can be also applied to a case employing the stator iron core according to one embodiment or a certain combination of more than two embodiments from the first through sixth embodiments.

[0125] FIG. 10 shows a cross sectional view of the compressor 16 containing the electric motor 14 taken along vertically. FIG. 11 shows a plan view of the compressor 16 when the electric motor is integrated, and FIG. 12 shows an enlarged view of a portion indicated as A of FIG. 11 .

[0126] The electric motor 14 is integrated into the housing 15 of the compressor and the like by shrink-fitting or press-fitting, appropriate electric wire connections are made, and the rotation axis 13 of the compressor 16 can be driven.

[0127] As shown in the enlarged view of FIG. 12 , the notch 11 is provided at the place opposite to the teeth portion, so that it is possible to fix the magnetic pole segment 3 by engaging the notch 11 with the winder chuck on winding the coil wire 6 . Since the coil wire 6 is wound around the teeth portion 3 f , it is possible to stably place the magnetic pole segment 3 by fixing the magnetic pole segment 3 using the notch 11 provided to the place opposite to the teeth portion 3 f . Further, on integrating the electric motor in the housing 15 of the compressor 16 , the notches 10 and 11 can be a passage for cooling gas or lubricating oil, and on inserting the electric motor by press-fitting, the contact area can be made smaller. Accordingly, it becomes easy to insert the electric motor into the housing 15 of the compressor 16 .

[0128] In the stator iron core of the electric motor according to the first through third embodiments, the magnetic pole segment is structured so that the bottom portion of the slot constituted by the back yoke portion and the teeth portion comes to have a curved line after the stator iron core is formed circularly. Accordingly, since the bottom portion of the slot has a curved line, on forming the iron core circularly or fixing the stator of the electric motor in the housing and the like by press-fitting or shrink-fitting, compression stress is not concentrated, which avoids to lose the magnetic performance of the magnetic material. Therefore, the embodiment of the invention does not reduce the efficiency of the electric motor, keeps the sufficient stiffness of the electric motor, and reduces the vibration or noise generated on driving the electric motor.

[0129] Further, the insulator member is provided to the teeth portion to cover the projected portion of the back yoke portion as well as the wall surface of the teeth portion. The wall surface of the back yoke portion of the insulator member and the wall surface of the teeth portion of the insulator member make an angle of around 90°. Therefore, possibility of injuring the coil wire by the projected portion on winding the coil wire is reduced.

[0130] Further, the notch is provided in the axial direction on the outer circumference of the back yoke portion at a place opposite to the connection portion, so that it becomes possible to reduce the stress generated at the connection portion on forming the iron core circularly or integrating the stator of the electric motor in the housing and the like by press-fitting or shrink-fitting, and reduce the damage caused by eddy current. Therefore, the embodiment of the invention does not reduce the efficiency of the electric motor, keeps sufficient stiffness of the electric motor, and reduces the vibration or noise generated during driving the electric motor.

[0131] Further, the notch is provided in the axial direction at a place opposite to the connection portion, so that the inner surface of the housing never contact the connection portion on integrating the stator in the housing by press-fitting or shrink-fitting, and the stator is seldom influenced by the dimensional precision of the housing. Further, since the holding force is applied to both sides of a place located far from the turning center of the connection portion, moment, which causes magnetic pole segments to contact without any space, is loaded to the connection portion. Therefore, each of the iron core members of the stator iron core of the electric motor becomes the same status to an iron core member made by punching (stamping out) as one circular (round) element, so that circularities of the outer circumference and the inner circumference of the stator of the electric motor become better. Consequently, air gap becomes uniform between the stator and the rotor of the electric motor on driving the motor, which eliminates magnetic unbalance, and further, reduces the noise or vibration of the electric motor.

[0132] Further, since the dimensional precisional allowance of the housing is around some tens μm in the radius direction at maximum of the circularity, the notch having a depth of more than 0.1 mm in the radius direction will be sufficient to obtain the above effect.

[0133] Further, the notch is provided on the outer circumference of the back yoke portion at a place opposite to the teeth portion, so that the stress of compression can be reduced on forming the iron core circularly or integrating the stator of the electric motor to the housing by press-fitting or shrink-fitting . Accordingly, the embodiment does not reduce the magnetic performance of the magnetic material nor reduce the efficiency of the electric motor, keeps sufficient stiffness, and reduces the vibration or noise generated on driving the electric motor.

[0134] Further, since the stator of the electric motor according to the fourth through sixth embodiments has V-shaped confronting surfaces of the end portions, the relationship of the location of each magnetic pole segment should be determined by each of the confronting surfaces of the connection portions and the confronting surfaces of the end portions. Since the confronting surfaces of the end portions have V-shapes, the movement of the stator in the radius direction will be restricted when the V-shaped end portions are faced. Accordingly, the mechanical precision of the stator of the electric motor will be directly determined. It is possible to easily secure the mechanical precision by improving the precision of punching the magnetic pole segment and so on. Therefore, the electromagnetic noise or vibration caused by a bad mechanical precision can be reduced, and further, the stator of the electric motor having high density of coiled wire, high efficiency, low noise, and low vibration can be easily obtained.

[0135] Each of the V-shaped confronting surfaces of the end portion is formed by two arc shapes, the first arc and the second arc. Centers of the arcs are approximately the same as the center of turning at the time of bending the thin connection portion of any of the magnetic pole segments, so that the centers of turning of the thin connection portions of magnetic pole segments are centers of the first arc and the second arc, respectively, and the centers of turning are turning points when the both far ends of magnetic pole segments are to be faced at last. Therefore, when the thin connection portion of the magnetic pole segment, which is located between the above specific magnetic pole segments, is bent at last, the magnetic pole segments are not disturbed each other, and the stator can be formed circularly out of plural magnetic pole segments. Accordingly, it is no need to determine an order of bending magnetic pole segments at bending process, and manufacturing the stator can be performed more flexibly in the aspect of facilities. Further, since the interference at bending process can be eliminated, the high reliability can be obtained in integrating the stator of the electric motor.

[0136] Since the jut is formed on joining the confronting surfaces of the end portions and is projected to an outer circumference of the stator as the top point. The top point of the jut is located inside of the outer circumference of the stator of the electric motor, so that the top point of the jut faces to the outer circumference side which are to be finally joined as both ends of magnetic pole segments. Accordingly, when the confronting surfaces of the end portions are joined, it is possible to easily blow an electric arc to the top point of the jut, which requires to be welded, and possible to weld the confronting surfaces sufficiently compared with welding to a flat plane or an arc plane of the outer circumference.

[0137] Having thus described several particular embodiments of the present invention, various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the present invention. Accordingly, the foregoing description is by way of example only, and is not intended to be limiting. The present invention is limited only as defined in the following claims and the equivalents thereto.