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`Motor Co., Inc. - Petitioners
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`

`I') THE PATENT OFFICE OF JAPAN (JP)
`I: OFFICIAL GAZETTE FOR UNEXAMINED PATENTS (A)
`
`II Disclosure Number
`·13 Date of Disclosure
`
`11-89128
`March ]0, 1999
`
`51 Int. Cl"
`
`Identification
`Symbols
`
`FI
`
`H02 K 1118
`3/46
`15/02
`15/095
`
`Request for Examination
`
`21 Application Number
`9-248321
`
`22 Filing Date
`September 12. 1997
`
`H 02 K 1118
`3/46
`15/02
`15/095
`
`C
`B
`G
`
`Not yet requested Number of Claims 11 OL
`(total 6 a es)
`
`71 Applicant 0000003078
`Toshiba Corp.
`72 Horikawa-cho, Saiwai-ku, Kawasaki, Kanagawa
`Prefecture
`
`72 Inventor ISHIHARA Hamhiko
`991-Anada-cho, Seto-chi, Aichi
`Toshiba Aichi Plant
`
`7~ Agent Attomey OOGO Norio
`and I other
`
`5,1 [Title of Invention]
`
`Stator of electric motor and its method of manufacture
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`57 [Abstract]
`[Subject] The stator of ,lll electric motor in which fixed units
`comprising coil bobbins about which coils have been wound
`and magnetic pole teeth arc mated to an (l]mular shaped stator
`iron core and its method of manufacturc, specifically the st,ltor
`of an electric motor that is asscmbled by connecting coil
`bobbins and its mcthod of manufacturc.
`rMeans of Resolutionl A coil bobbin unit 20 is manufactured
`by connecti ng a predetermined Humber of coil bobbins 23 via
`connecting members ]2. Each coil bobbin 23 is wound by wire
`22. after which the coil bobbin unit 20 is formed into annular
`shape, Jllelted to elll annular slwpcd stator core 29 and fixed in
`place to complete asscmbly of thc st,ltor 24.
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`IScope of Patent Claim]
`I Clai III II The stator of ~1Il electric motor comprising coils,
`a coil bobbin unit comprising coil bobbins about whicll coils are wound thM helVe conllectionll1embers, s,lic! coil
`bobbin units being able to be coupled to other coil bobbins via the aforementioned connection members so as to
`freely piyot with them,
`magnetic pole teeth to which the ,1 forementionec! coil bobbins arc fitted and fixed, and
`a fixed iron core to which are mated ,md held in place a plurality of coil bobbin units to which the aforementioned
`magnetic pole teeth had been fitted and fixed , said units being formed in annular shape via the aforementioned
`connection members.
`[Claim 21 The stator of an electric motor of Claim 1 in which the aforementioned cOIUlection member is fonned by a
`stmcture in which a recess member and a protmsion member are fitted together so as to freely pivol.
`I Claim 31 The stator of an electric motor of Claim l in which the aforementioned cOlUlection member is formed
`from an insertion pin and an insertion hole.
`[Claim --I- J The stator of an eleetJic motor of Claim 1 in which Ule aforementioned magnetic pole teeth and coil
`bobbins arc integrated.
`[Claim 5] The stator of an electric motor of Claim 1 in which the aforementioned coil bobbins are split in two with
`upper and lower symmetry relative to the axial direction of the rolor of the electric motor.
`[Claim G] The stator of an electric motor of Claim 1 in which projections to hold in place crossover wires between
`coils of the same phase or coil terminal connection members are installed in tlle aforementioned coil bobbins.
`[Claim 7] The stator of an electric motor of Claim 1 in which flange members that close the slots between adjacent
`coil bobbins when forming the a.forementioned coil bobbins in annular shape are formed in the aforementioned coil
`bobbins.
`[Claim 8] The stator of an electric motor of Claim 1 in which insulating partition plates that fasten the connection
`members of adjacent coil bobbins are installed between the aforementioned coil bobbins.
`[Claim 91 The stator of an electric motor of Claim 1 in which at least one of the aforementioned coil bobbins or the
`aforementioned partition plates is formed from electrical insulating material having high magnetic permeability.
`rClaim 101 A method of manufacturing the stator of an electric motor in which units comprising coil bobbins about
`which coils have been wound ,md magnetic pole Leeth are mated to an anllular shaped stator iron core, whcrein said
`method comprises a stcp in which the aforementioned coil bobbins are connected in band shape via a predetermined
`number of connection members and a step of winding of wire about the aforementioned coil bobbins.
`[Claim 11] A method of manufacturing the stator of an electric motor in which units comprising coil bobbins about
`which coils have been wound and magnetic pole teeth are mated to an annular shaped yoke iron core, whercin said
`method comprises a step of winding of wire about the stator of the aforementioned coil bobbins, a step of
`connecting said coil bobbins via connection members, and a step of connecting wound wire of the same phasc.
`[Detailed Description of the Invention J
`[OOO}]
`[Technical Field of Invention] The present invention concems the stator of an elcctric motor in which fixed units
`of coil bobbins comprising a plurality of connected frames about which eoils have been wound ,mel magnetic pole
`teeth are mated to an annular shaped yoke iron core and its method of manufacture, especially to the st~ltor of an
`electric motor that is assembled by manufacturing split coil bobbins and then connccting them.
`[0002J
`[Related Art] The stalor (stator) of an electric molor that uses coil bobbins has the configuration presented in lhc
`gazette of Japancsc Kokai Publication Hei-7-245895. Specifically, as explained based on Figure 10 and Figurc 11.
`the stator (stator) 8 comprises a stator core I. coils 4, and coil bobbins 5 made of resin, while the rotor (rotor) l () is
`inserted in the stator 8 and is rcmovably supported so ,1S to Creely rotate. A plurality of coil bobbins 5 are connccted
`in b,lI1d shape at uniform separations continuously cOIUlected via thin parts 15a. The properties of the coil bobbins 5
`prefembly would be insulating. but they nced not be made of resin.
`[0003 J Magnetic pole tceth 2 arc first fitted to each of the coil bobbins 5 in the manufacture of the stator 8. The
`magnetic pole teeth 2 arc columnar shaped but a crescent shaped expanded rotor-facing member 2a is formed at one
`tip of each of the teeth. I n short, the thin parts 15a arc bent so that the rotor-facing member 2a of each of the
`magnetic pole teeth 2 of the coil bobbins 5 facing the rotor 10 woule! face Ihe outer circumference. as a resull of
`which a rouncled shape Opposile from the normal asscmbled state is adoptcd. Thcn. thc rotor-facing member 2;1 of
`each of the \l1,lgnclic pole teelh 2 is posilioned and fi"ed in place so as to be at a predelermined position on wound
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`wire (not illustnlted). E;lch of the coil bobbins 5 is coupled on the outer-diameter side rather than 011 the inner(cid:173)
`dimneter side, as a result of the magnetic pole teeth 2 C,1I1 be ,yidely opened.
`[O()O.tlln this state. predetennined magnetic pole teeth 2 are positioned on a reference line for wire winding and the
`wire that is wound via a winding device can be aligned on each of the coil bobbins 5. After all coil bobbins 5 have
`been woullCL thc:y would be reverted to their normal state to complete assembly of the st(ltor core I and the stator, in
`turn.
`1000S]
`I Problems Solyed h)' the Invention] In the aforementioned method of manufacturing the st(ltor of an electric
`motoL a plurality of coil bobbins are integrated as a bmld shapcd continuous coil bobbillllnit with thc discretc coil
`bobbins held at uniforlll se parations by thin parts. Consequently, large molding dies arc required ill the manufacture
`of the coil bobbin units and the manufacturing properties me quite poor.
`[()OnG] Structmally, coil bobbins are susceptible to deformation, including shifting and warping, when formed into
`annular shape and coil bobbins or magnetic pole teeth must be held in place by a jig when assembled. An additional
`dcfect is thc fact th(lt a fixed spatial distance must be lll(lintained to ensure insul(lting properties between coils. This
`constitutes a high r(lte of spatial occupation that complic(ltes the winding of wire (lbout each coil.
`10007] The present invention was devised in light of the aforementioned circumst(lnces. The objective is to provide
`a method of manuf,lcture that does not necessitate a large molding die in the manuf(lcture of coil bobbin units.
`[00081 In addition, the stator of an electric motor that has good assembly properties is provided with a structure that
`does not suffer deformation such as shifting or warping (lS a result of closure of the slot by adjacent rotor-facing
`members when fonning coil bobbins in annular sh(lpe.
`(0009J Furthermore, the stator of an electric motor in which the separation for insulation can be reduced as ,I result
`of the installation of partition plates that insulate adjacent coils.
`(00101
`(Means of Solving the Problems] The present invention provides the stator of an electric motor comprising coils, ,I
`coil bobbin unit comprising coil bobbins about which coils are wound that have connection members, said coil
`bobbin units being able to be coupled to other coil bobbins via the aforementioned eOllnection members so as to
`freely pivot with them, magnetic pole teeth to which the aforementioned coil bobbins arc fitted and fixed, and a
`fixed iron core to which arc mated and held in place a plur(llity of coil bobbin units to which the aforementioned
`magnetic pole teeth h(ld becn filled and fixed, said units being formed in ammlar slwpe via the aforementioned
`conncction members .
`(00111 In addition, the present invcntion concerns the st(ltor of an electric motor in which the aforementioncd
`conncction member is formed by a stmcture in which a recess member and a protrusion membcr are fitted together
`so as to freely pivot.
`(0012 J In addition, the present invention concerns the stator of an electric motor in which the aforementioned
`connection member is formed from an insertion pin and (lll insertion hole.
`[00131 In addition, the aforementioned invention concerns the stator of an electric motor in which the
`aforementioned magnetic pole teeth and coil bobbins are integrated.
`[OOU 1 [n addition, the aforemcntioned invention concerns the stator of an electric motor in which the
`aforementioned coil bobbins are split in two with upper (lndlower symmetry relative to the axial direction of the
`rotor of the electJic motor.
`(00 151 In addition. the aforcmcntioned invention concerns the stator of an e1ectJic Illotor in which projections 10
`hold in place crossover wires bctwcen coils of the S(ll1le plwse or coil tenninal connection members arc inst:Jlled in
`thc aforementioned coil bobbins.
`[0016] In clddition, the present invention concerns lhe st(ltor of an electric motor in which Oange members thaI close
`the slots between 'Idjacent coil bobbins when forming the aforementioned coil bobbins ill annular shape arc formed
`in the clforementioned coil bobbins.
`10017J In addition. the prese nt invention concerns the st(ltor of an electric motor in which insulating parlition plates
`t hat fasten the connection members of adjacent coil bobbins are installed between the aforementioned coil bobbins.
`100181 In clddition. the present invention concerns the stMor of an electric motor in which at least one of the
`aforeillentioned coil bobbins or the aforementioned p,lJ1ition plates is formed from electrical insulCl1ing lllateri:ll
`having high magnetic pcrmcabi lity .
`10019 J [n addition. lh