`
`(1)
`(19) Japan Patent Office (JP) (12) Publication of Patent Application (A)
`
`Unexamined Patent Publication No. H11-341717
`
`(11) Published Patent Application
`Number
`Unexamined Patent Publication
`No. H11-341717
`(43) Publication date:
`December 10th, 1999
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`F1
`H02K 1/18
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` 15/02
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`(51) Int.Cl.6
` H02K 1/18
` 3/46
` 15/02
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`Identification Code
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`Examination requested: none Number of claims: 32 OL (14 pages in total）
`
`(21) Application No.: H10-147077
`
`(22) Application Date: May 28th, 1998
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`(71) Applicant: 000006242
` Matsushita Seiko Co., Ltd.
` 6-2-61 Imafuku Nishi, Joto-ku,
` Osaka-shi, Osaka
`(72) Inventor: Hiroyuki Inoue
` Matsushita Seiko Co., Ltd.
` 6-2-61 Imafuku Nishi, Joto-ku,
` Osaka-shi, Osaka
`(72) Inventor: Toyoji Okayama
` Matsushita Seiko Co., Ltd.
` 6-2-61 Imafuku Nishi, Joto-ku,
` Osaka-shi, Osaka
`(74) Agent Patent Attorney:
` Tomoyuki Takimoto (and one other)
`
`
`(54)Title of the Invention: STATOR OF MOTOR AND METHOD OF MANUFACTURING THE SAME
`
`(57) [Abstract]
`[Object] To provide a stator of a motor that
`requires no accuracy of coupling between yoke
`portions and tooth portions and can achieve a
`small cross-sectional area so
`that motor
`efficiency is not degraded.
`
`[Solving means] Coil conductors 9 are wound on
`tooth portions 12 of unit core members 8 each
`including a yoke portion 11 having an arch-
`shaped outer circumference surface and an inner
`circumference formed as a flat surface portion 1
`and a tooth portion 12 having a pole shoe portion
`4 formed as a rotor facing surface 3 on an inner
`circumference end and provided to the flat
`surface portion 1 of the yoke portion 11. Then,
`the unit core members 8 are annularly arranged
`with both end surfaces of the yoke portions 11 in
`close contact with each other. Thus, a stator of a
`motor requiring no accuracy of coupling between
`the yoke portions and the tooth portions and
`
`
`
`causing no degradation in motor efficiency can
`be obtained.
`
`
`
`
`
`1 flat surface portion
`3 rotor facing surface
`4 pole shoe portion
`8 unit core member
`9 coil conductor
`11 yoke portion
`12 tooth portion
`
`NIDEC and HONDA - Ex. 1009
`Nidec Corporation and American Honda
`Motor Co., Inc. - Petitioners
`
`1
`
`

`

`
`
`(2)
`
`[Claims]
`the stator
`[Claim 1] A stator of a motor,
`comprising: unit core members each formed with
`unit cores each including a yoke portion core
`having an outer circumference surface forming a
`cylindrical shape and an inner circumference
`formed as a flat surface portion and a tooth
`portion core having a pole shoe portion formed as
`a rotor facing surface on an inner circumference
`end and provided to the flat surface portion of the
`yoke portion core; and coil conductors each
`wound on corresponding one of tooth portions of
`the unit core members, wherein the unit core
`members are annularly arranged with both end
`surfaces of the yoke portions of the unit core
`members in close contact with each other in a
`circumference direction.
`
`[Claim 2] The stator of a motor according to claim
`1, wherein the coil conductors are each wound on
`the corresponding one of the tooth portions of the
`unit core members in a trapezoidal stacked layer
`arrangement form in such a manner that a cross-
`sectional area gradually increases toward an
`inner circumference surface of the yoke portion.
`
`[Claim 3] A method of manufacturing a stator of a
`motor, the method comprising: punching unit
`cores in alternate directions with a direction
`changing for every unit of n arrays (n being an
`integer equal to or larger than 2) of unit cores, the
`unit cores each including a yoke portion core
`having an outer circumference surface forming a
`cylindrical shape and an inner circumference
`formed as a flat surface portion and a tooth
`portion core having a pole shoe portion formed as
`a rotor facing surface on an inner circumference
`end and provided to the flat surface portion of the
`yoke portion core.
`
`[Claim 4] The method of manufacturing the stator
`of a motor according to claim 3, wherein the unit
`cores are punched in a unit of unit cores, with a
`cross-sectional area of a wound portion of a coil
`conductor increased or reduced with the inner
`circumference flat surface portion of the yoke
`portion shifted toward an outer circumference
`side or an inner circumference side.
`
`[Claim 5] A method of manufacturing a stator of a
`motor, the method comprising forming a unit core
`member with unit cores stacked by pressing,
`pressure welding, or with an adhesive using
`pressing force of manufacturing equipment in a
`punching step for the unit cores.
`
`
`
`Unexamined Patent Publication No. H11-341717
`
`[Claim 6] A method of manufacturing a stator of a
`motor, the method comprising forming a unit core
`member by punching and stacking unit cores with
`a mold and a jig or a material heated in a
`punching step for the unit cores.
`
`the stator
`[Claim 7] A stator of a motor,
`comprising: unit core members each formed with
`unit cores each including a yoke portion core
`having an arch-shaped surface formed as an
`arch-shaped
` outer circumference surface
`provided with a coupling recess and an inner
`circumference formed as a flat surface portion
`and a tooth portion core having a pole shoe
`portion formed as a rotor facing surface on an
`inner circumference end and provided to the flat
`surface portion of the yoke portion core; coil
`conductors each wound on corresponding one of
`tooth portions of the unit core members; and a
`flat plate member provided with coupling
`protrusions coupled with the coupling recesses
`formed on the arch-shaped surfaces of the unit
`core members, wherein with
`the
`flat plate
`member, the unit core members are annularly
`arranged with both end surfaces of the yoke
`portions of the unit core members in close
`contact with each other in a circumference
`direction.
`
`[Claim 8] The stator of a motor according to claim
`1 or 7, wherein the unit core members are each
`formed with the unit cores after the punching
`stacked by resin insert in a resin insert member
`including a resin mold and a jig.
`
`[Claim 9] The stator of a motor according to claim
`1 or 3, wherein a resin film is formed on the pole
`shoe portion in such a manner that an angle Q,
`between both end surfaces of the yoke portion,
`on which the resin film is not formed so that the
`unit core members
`formed by resin
`insert
`stacking are able to be joined to each other while
`being
`in close contact with each other,
`is
`substantially same as an angle between both end
`surfaces of the pole shoe portion on the inner
`surface end.
`
`[Claim 10] The stator of a motor according to
`claim 7, wherein the flat plate member is made of
`a metal material, a non-metal material, a resin
`material, a leather material, or other like material
`and has a strip form and is provided with coupling
`protrusions coupled with the coupling recesses
`formed on the unit core members formed by resin
`insert stacking, coupling portions of the unit core
`members are fixed with an adhesive, by welding,
`or by other like method, and the coil conductors
`
`2
`
`

`

`
`
`(3)
`
`are wound on the unit core members being fixed
`to the flat plate member.
`[Claim 11] The stator of a motor according to
`claim 7, wherein a distance L between the
`coupling protrusions formed on the flat plate
`member is formed with the coupling protrusions
`arranged in such a manner that the distance
`corresponds to an angle Q between both end
`surfaces of each of the yoke portions of the unit
`core members.
`
`[Claim 12] The stator of a motor according to
`claim 1, wherein the unit cores each include: a
`yoke portion core having an arch-shaped surface
`formed as an arch-shaped outer circumference
`surface provided with a coupling protrusion and
`an inner circumference formed as the flat surface;
`and the tooth portion core having the pole shoe
`portion formed as the rotor facing surface on the
`inner circumference end and provided to the flat
`surface portion of the yoke portion core.
`
`[Claim 13] A method of manufacturing a stator of
`a motor, the method comprising: forming a unit
`core member by stacking unit cores each having
`an arch-shaped outer circumference surface
`provided with a coupling protrusion through the
`punching step in the method according to claim 5.
`
`[Claim 14] A method of manufacturing a stator of
`a motor, the method comprising: forming a unit
`core member by stacking unit cores each having
`an arch-shaped outer circumference surface
`provided with a coupling protrusion through the
`punching step in the method according to claim 6.
`
`[Claim 15] The stator of the motor according to
`claim 8, wherein the unit core members are each
`formed by stacking unit cores each having an
`arch-shaped
`outer
`circumference
`surface
`provided with a coupling protrusion by resin
`insert.
`
`[Claim 16] The stator of the motor according to
`claim 9, wherein the unit core members are each
`formed by stacking unit cores each having an
`arch-shaped
`outer
`circumference
`surface
`provided with a coupling protrusion by resin
`insert.
`
`[Claim 17] A stator of a motor, wherein unit core
`members, each being formed by stacking unit
`core each having an arc-shaped outer
`circumference surface provided with a coupling
`protrusion, are formed, a flat plate member that is
`made of a metal material, a non-metal material, a
`resin material, a leather material, or other like
`material and has a strip form is provided with
`
`
`
`Unexamined Patent Publication No. H11-341717
`
`the coupling
`coupling notches coupled with
`protrusions
`formed on unit core members,
`coupling portions of the unit core members are
`fixed with an adhesive, by welding, or by other
`like method, coil conductors are wound on the
`unit core members, and the unit cores are
`annularly arranged.
`
`[Claim 18] The stator of a motor according to
`claim 17, wherein the notches are alternately
`formed on upper and lower sides of the flat plate
`member to form a zigzag form.
`
`[Claim 19] The stator of a motor according to
`claim 17, wherein the notches are formed on
`lower sides of the flat plate member.
`
`[Claim 20] The stator of a motor according to
`claim 7, wherein resin insert molding is performed
`for unit cores, each having an arch-shaped outer
`circumference surface provided with a coupling
`recess, to integrally form insulators for the unit
`core members and the flat plate member, with
`which the unit core members are coupled to each
`other, with resin.
`
`[Claim 21] The stator of a motor according to
`claim 17, wherein resin insert is performed for
`unit cores, each having an arch-shaped outer
`circumference surface provided with a coupling
`protrusion, to integrally form insulators for the unit
`core members and the flat plate member, with
`which the unit core members are coupled to each
`other, with resin.
`
`[Claim 22] The stator of a motor according to
`claim 1, wherein the coil conductors are wound
`on the unit core members formed by insert
`molding in such a manner that each unit of n pair
`of unit cores are coupled to each other with a
`ring, and the unit core members are annularly
`arranged with one unit having a position shifted
`from another unit.
`
`[Claim 23] The stator of a motor according to
`claim 22, wherein a ring with which the unit core
`members are coupled is provided with fitting
`holes in which ribs provided to the unit core
`members coupled with positions shifted are
`inserted.
`
`[Claim 24] A method for manufacturing a stator of
`a motor, the method comprising winding a coil
`conductor on a unit core member in a state of
`being coupled to a flat plate member.
`
`[Claim 25] A method of manufacturing a stator of
`a motor, the method comprising: inserting a unit
`of n unit cores, insert molded to be coupled to
`
`3
`
`

`

`
`
`(4)
`
`each other with a ring, in a jig A; fixing the unit
`with a jig B; and sequentially winding the coil
`conductors on the unit core members by spindle
`winding.
`
`[Claim 26] The stator of a motor according to
`claim 1, wherein n unit core members on which
`the coil conductors are wound are provided to a
`flat plate member, and the flat plate member are
`formed into a round shape and have end portions
`coupled to each other in such a manner that both
`end surfaces of the yoke portions of the unit core
`members come into close contact with each
`other.
`
`[Claim 27] The stator of a motor according to
`claim 26, wherein the flat plate member is
`coupled by welding, pressure welding, or with an
`adhesive.
`
`[Claim 28] The stator of a motor according to
`claim 26, wherein the flat plate member is
`coupled by caulking.
`
`[Claim 29] The stator of a motor according to
`claim 26, wherein the flat plate member has end
`portions provided with
`coupling portions
`protruding outward, and the coupling portions are
`aligned with each other and are coupled to each
`other with a screw or a rivet.
`
`[Claim 30] The stator of a motor according to
`claim 26, wherein the flat plate member has both
`end portions that are formed as coupling portions
`having fitting holes in a form in which a coupling
`pin is inserted and are coupled to each other.
`
`[Claim 31] The stator of a motor according to
`claim 1, wherein the unit core members annularly
`arranged are coupled to each other with a ring
`formed of a shrinkable material.
`
`[Claim 32] The stator of a motor according to
`claim 1, wherein the unit core members are
`annularly arranged with both end surfaces of the
`tooth portions, each having the pole shoe portion
`with the rotor facing surface, in close contact with
`each other.
`
`[Detailed Description of the Invention]
`[0001]
`[Technical field to which the invention pertains]
`The present invention relates to a stator of a
`motor formed by winding coil conductors on unit
`cores, each provided with a yoke portion core
`and a tooth portion, and then annularly arranging
`the unit cores, and a method of forming the
`stator.
`
`[0002]
`
`
`
`Unexamined Patent Publication No. H11-341717
`
`[Conventional technique] One motor stator that
`has
`recently been popular
`is
`formed by
`separately preparing a yoke portion on an outer
`diameter side and a plurality of tooth portions for
`forming slots, winding coil conductors on the
`tooth portions, and
`then coupling the tooth
`portions to the yoke portion, so that the winding
`operation can be easily performed. In this
`context, a demand for a configuration using a unit
`member in which the yoke portion and the tooth
`portion are integrally formed and thus no coupling
`accuracy between the yoke portion and the tooth
`portion is required have been increasing.
`
`[0003] Fig. 35 to Fig. 37 illustrate a conventional
`stator of a motor of this type that has been
`developed. Thus, a configuration
`thereof
`is
`described with reference to Fig. 35 to Fig. 37.
`
`[0004] As illustrated in the figures, a yoke portion
`core 104, having an outer circumference forming
`a cylindrical form, and an inner circumference
`formed to be a polygonal shape with a plurality of
`flat surface portions 101 each provided with a
`coupling recess 103 including a recess side notch
`102 for retaining, is formed by punching a core
`plate. A plurality of tooth portion cores 109, each
`having one end provided with a coupling
`protrusion 105 and a retaining protrusion side
`notches 106 to be coupled with a corresponding
`one of the recesses 103 formed on the yoke
`portion core 104 and having the other end
`provided with a pole shoe portion 108 having a
`rotor
`facing surface 107, are
`radially and
`concentrically arranged while being shifted to
`each other in a radial direction on the inner side
`of the yoke portion core 104, and are punched
`separately from the yoke portion core 104. After
`the tooth portion cores 109 are stacked to a
`predetermined height, the tooth portions 109A
`are provided with coil frames 111 on which coil
`conductors 110 are wound, and then the coil
`conductors 110 are wound.
` Then,
`the
`protrusions 105 of the tooth portions 109A are
`coupled to the recesses 103 of the yoke portion
`104A so that the tooth portions 109A provided
`with the coil conductors 110 are coupled to the
`yoke portion 104A, whereby the stator of the
`motor is formed.
`
`[0005]
`[Problem to be solved by the invention] In such a
`conventional stator of the motor, the yoke portion
`104A and the tooth portions 109A are integrated
`
`4
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`

`

`
`
`(5)
`
`with the protrusions 105 of the tooth portions
`109A coupled with the recesses 103 of the yoke
`portion 104A. Thus, the recesses 103 of the
`yoke portion 104A and the protrusions 105 of the
`tooth portions 109A need
`to be accurately
`formed. Furthermore, the punching results in a
`large cross-sectional area, leading to low motor
`efficiency.
`
`[0006] The punching of the annular shaped yoke
`portion core 104 and the tooth portions 109A is
`plagued by low material yield and requires a
`complicated mold and the step of coupling the
`yoke portion 104A and the tooth portions 109A to
`each other.
`
`[0007] The present invention is made in view of
`the problems described above, and an object of
`the present invention is to provide a stator of a
`motor that requires no accuracy for coupling a
`yoke portion and a tooth portion to each other
`and can achieve a small cross-sectional area so
`that motor efficiency is not degraded.
`
`[0008] A further object of the present invention is
`to provide a method of manufacturing a stator of
`a motor, featuring high material yield, achievable
`with a simple mold, and requiring no step for
`coupling the yoke portion and the tooth portion to
`each other.
`
`[0009]
`[Means for solving the problem] A stator of a
`motor for achieving the object includes: unit core
`members each formed with unit cores each
`including a yoke portion core having an outer
`circumference surface forming a cylindrical shape
`and an inner circumference formed as a flat
`surface portion and a tooth portion core having a
`pole shoe portion formed as a rotor facing
`surface on an inner circumference end and
`provided to the flat surface portion of the yoke
`portion core; and coil conductors each wound on
`corresponding one of tooth portions of the unit
`core members by stacking
`the unit core
`members, wherein the unit core members are
`annularly arranged with both end surfaces of the
`yoke portions of the unit core members in close
`contact with each other in a circumference
`direction.
`
`[0010] With the present invention, a stator of a
`motor that requires no accuracy of coupling
`between yoke portions and tooth portions and
`can achieve a small cross-sectional area so that
`motor efficiency is not degraded can be obtained.
`
`
`
`Unexamined Patent Publication No. H11-341717
`
`[0011] A method of manufacturing a stator of a
`motor for achieving the object described above
`includes punching unit cores alternately with a
`direction changing for every unit of n arrays (n
`being an integer equal to or larger than 2) of unit
`cores, the unit cores each including a yoke
`portion core having an outer circumference
`surface forming a cylindrical shape and an inner
`circumference formed as a flat surface portion
`and a tooth portion core having a pole shoe
`portion formed as a rotor facing surface on an
`inner circumference end and provided to the flat
`surface portion of the yoke portion core.
`[0012] With the present invention, a method of
`manufacturing a stator of a motor, featuring high
`material yield, achievable with a simple mold, and
`requiring no step for coupling the yoke portion
`and the tooth portion to each other can be
`obtained.
`
`[0013]
`invention] The
`the
`for carrying out
`[Modes
`present invention includes a stator of a motor
`including: unit core members each formed with
`unit cores each including a yoke portion core
`having an outer circumference surface forming a
`cylindrical shape and an inner circumference
`formed as a flat surface portion and a tooth
`portion core having a pole shoe portion formed as
`a rotor facing surface on an inner circumference
`end and provided to the flat surface portion of the
`yoke portion core; and coil conductors each
`wound on corresponding one of tooth portions of
`the unit core members by stacking the unit core
`members, wherein the unit core members are
`annularly arranged with both end surfaces of the
`yoke portions of the unit core members in close
`contact with each other in a circumference
`direction. With this configuration, the yoke
`portion and
`the
`tooth portion are
`integrally
`formed, and thus a stator of a motor that requires
`no accuracy of coupling between
`the yoke
`portions and the tooth portions and can achieve a
`small cross-sectional area so
`that motor
`efficiency is not degraded can be obtained.
`
`[0014] The present invention further includes a
`method of manufacturing a stator of a motor
`including: punching unit cores
`in alternate
`directions with a direction changing for every unit
`of n arrays (n being an integer equal to or larger
`than 2) of unit cores, the unit cores each
`including a yoke portion core having an outer
`circumference surface forming a cylindrical shape
`and an inner circumference formed as a flat
`surface portion and a tooth portion core having a
`
`5
`
`

`

`
`
`(6)
`
`pole shoe portion formed as a rotor facing
`surface on an inner circumference end and
`provided to the flat surface portion of the yoke
`portion core. With this configuration, no yoke
`portion core having an annular form needs to be
`punched, and only a unit core of a single type
`needs to be punched, whereby a high yield can
`be achieved. Furthermore, a simple mold can be
`used and a higher material yield can be achieved.
`
`[0015] Embodiments of the present invention are
`described below with reference to Fig. 1 to Fig.
`34.
`
`[0016]
`[Embodiments] (First embodiment) As illustrated
`in Fig. 1 to Fig. 6, in a punching step 7, a mold
`and jig are used that are designed in such a
`manner that unit cores 6 are punched in alternate
`directions with a direction changing for every unit
`of n unit cores 6 (n being an integer equal to or
`larger than 2), the unit cores 6 each including a
`yoke portion core 2 having an arch-shaped outer
`circumference
`surface
`and
`an
`inner
`circumference formed as a flat surface portion 1
`and a tooth portion core 5 that has a pole shoe
`portion 4 formed as a rotor facing surface 3 on an
`inner circumference end and provided to the flat
`surface portion 1 of the yoke portion core 2. The
`unit cores 6, obtained by the punching, in a
`predetermined number for achieving a required
`height are stacked by pressing, pressure welding,
`or with an adhesive using pressing force of
`manufacturing equipment, to form a unit core
`member 8.
`
`[0017] The unit core member 8 is provided with
`an insulator (not illustrated), and a coil conductor
`9 is wound around the unit core member 8 in a
`winding step 10. In this process, the winding is
`performed on a tooth portion 12 in a trapezoidal
`stacked
`layer arrangement
`form
`in such a
`manner that a wound portion gradually widens
`toward an inner circumference surface of a yoke
`portion 11 of the unit core member 8. Then, in an
`arrangement step 13, the unit core members 8
`each having
`the coil conductor 9 wound
`therearound are arranged with both end surfaces
`of the yoke portions 11 in close contact with each
`other in a circumference direction, whereby a
`stator is manufactured.
`
`[0018] In the configuration described above, the
`unit core member 8 is formed with the yoke
`portion 11 and the tooth portion 12 integrally
`
`
`
`Unexamined Patent Publication No. H11-341717
`
`formed. Thus, unlike in a configuration where the
`yoke portion 11 and the tooth portion 12 are
`separately formed and coupled to each other with
`recesses and protrusions, the recesses and the
`protrusions, for coupling the yoke portion 11 and
`the tooth portion 12 to each other, need not to be
`accurately formed. Motor efficiency can thus be
`prevented from degrading with a reduced cross-
`sectional area, compared with the conventional
`configuration where the yoke portion and the
`tooth portion are separately formed, and it is a
`matter of course that a coupling step for coupling
`the yoke portion and the tooth portion to each
`other is not required in the first place.
`
`[0019] The coil conductor 9 wound on the tooth
`portion 12 is wound in a trapezoidal stacked layer
`arrangement form in such a manner that the
`cross-sectional area of
`the wound portion
`gradually increases toward a flat surface portion
`1 on the inner circumference of the yoke portion
`11. Thus, a larger number of coil conductors 9
`can be wound, whereby an attempt to achieve a
`higher performance can be facilitated.
`
`[0020] Each n (n being an integer equal to or
`larger than 2) unit cores 6, each including the
`yoke portion core 2 and the tooth portion core 5
`that are integrally formed, as a single unit are
`manufactured at a time by punching, whereby a
`higher material yield can be achieved compared
`with a configuration where the yoke portion core
`2 and the tooth portion core 5 are separately
`punched.
`
`[0021] The unit cores 6 may each be punched in
`a unit of unit cores with the inner circumference
`surface portion 1 of the yoke portion core 2
`shifted toward the outer circumference side or the
`inner circumference side. Thus, the unit cores 6
`may be punched with the cross-sectional area of
`the wound portion of
`the coil conductor 9
`increased or
`reduced, whereby
`the cross-
`sectional area of the wound portion can be easily
`adjusted.
`
`[0022] In the punching step 7 for the unit cores 6,
`the unit core member 8 is formed by stacking,
`achieved with pressure contact, pressure
`welding, or adhesion layers using pressing force
`of manufacturing equipment, whereby a cost
`reduction can be achieved.
`
`[0023] In the punching step 7, the punching can
`be performed with a mold or a jig heated, or with
`a heating unit provided to heat core materials
`
`6
`
`

`

`
`
`(7)
`
`before being inserted in the punching mold or the
`jig so that the core materials can be heated and
`then punched and stacked, whereby the unit
`cores 6 can have a higher resistance against
`peeling.
`
`[0024] (Second embodiment) As illustrated in Fig.
`7 to Fig. 10, a unit core member 8A is formed
`with unit cores 6A, each including a yoke portion
`core 2A having an arch-shaped outer
`circumference surface as an arch-shaped surface
`14 provided with a pair of coupling recesses 15
`separated
`from each other, and an
`inner
`circumference surface as the flat surface portion
`1, and provided with the tooth portion core 5
`having a rotor facing surface 3 formed on a pole
`shoe portion 4 on an inner circumference end,
`stacked by resin insert in an insert molding
`member 16 including a resin mold and a jig. In
`the forming process, a resin film 17 serving as an
`insulator is not formed on both end surfaces of
`the yoke portion 11A of the unit core member 8A,
`and is formed over an angle Q defined with both
`end surfaces of the yoke portion 11A and the
`pole shoe portion 4 at the inner circumference
`end.
`
`[0025] Then, the coil conductor 9 is wound on the
`unit core member 8A on which the resin film 17 is
`formed. The unit core members 8A arranged in
`the annular form with both end surfaces of the
`yoke portions 11A in close contact with each
`other in the circumference direction are held with
`a flat plate member 19 provided with protrusions
`18 that engage with the coupling recesses 15
`formed on the arch-shaped surface 14, whereby
`a stator is formed.
`
`[0026] In the configuration described above, the
`stator is formed by holding the unit core members
`8A with the protrusions 18 formed on the flat
`plate member 19 engaged with the coupling
`recesses 15 formed on the arch-shaped surface
`14 of the unit core member 8A, whereby the
`stator can be rigidly held to be prevented from
`deforming.
`
`[0027] The unit core member 8A is formed with
`the unit cores 6A, formed by punching, stacked
`with a resin insert in the insert molding member
`16 including the resin mold and the jig, whereby
`the stacking and insulating of the unit cores 6A
`can be achieved in a single step, whereby the
`number of steps can be reduced.
`
`[0028] The unit core members 8A stacked with
`
`
`
`Unexamined Patent Publication No. H11-341717
`
`the resin insert are tightly joined with the resin
`film 17 formed on the pole shoe portion 4 with the
`angle Q between both end surfaces of the yoke
`portion 11A on which the resin film 17 is not
`formed substantially matching an angle between
`both end surfaces of the pole shoe portion 4 at
`the inner circumference end, whereby the unit
`core members 8A can be accurately arranged in
`the annular form.
`
`[0029] (Third embodiment) As illustrated in Fig.
`11, a flat plate member 19A that is made of a
`metal material, a non-metal material, a resin
`material, a leather material, or the like and has a
`strip shape is formed with a distance L, between
`pairs of coupling protrusions 18A with which the
`coupling recesses 15 formed on the unit core
`member 8A on which the resin film 17 is formed
`are coupled, corresponding to the angle Q
`between both end surfaces of the yoke portion
`11A of the unit core member 8A. The protrusions
`18A formed on the flat plate member 19A are
`coupled with the recesses 15 formed on the unit
`core members 8A with the coupled portion fixed
`with an adhesive or by welding. Coil conductors
`(not illustrated) is wound on n unit core members
`8A fixed to the flat plate member 19A. Thus, the
`flat plate member 19A holds the unit core
`members 8A arranged in the annular form with
`both end surfaces of the yoke portions 11A in
`close
`contact with each other
`in
`the
`circumference direction, and thus a stator is
`formed.
`
`[0030] In the configuration described above, the
`coupling protrusions 18A, with which the coupling
`recesses 15 formed on the unit core members 8A
`are coupled, are formed on the flat plate member
`19A, and the coupled portion of the unit core
`member 8A is fixed. The coil conductor is wound
`in the fixed state thus achieved, and thus can be
`easily wound.
`
`[0031] The distance L between the coupling
`protrusions 18A formed on the flat plate member
`19A corresponds to the angle Q between both
`end surfaces of the yoke portion 11A of the unit
`core member 8A, whereby the unit core members
`8A can be accurately annularly arranged and
`rigidly held by the flat plate member 19A.
`
`[0032] (Fourth embodiment) As illustrated in Fig.
`12 to Fig. 14, unit core members 8B are formed
`as follows. Specifically, unit cores 6B, each
`including a yoke portion core 2B having an arch-
`
`7
`
`

`

`
`
`(8)
`
`shaped outer circumference surface as the arch-
`shaped surface 14 provided with the coupling
`portion 20, and an inner circumference surface
`as the flat surface portion 1 serving provided with
`the tooth portion core 5 having the rotor facing
`surface 3 formed on the pole shoe portion 4 on
`the inner circumference end, are punched with a
`mold or a jig heated or by being heated with a
`heating unit before being inserted in the punching
`mold or the jig. The unit cores 6B thus punched,
`in a number suitable for achieving a desired
`height, are stacked by stacking, achieved with
`pressure contact, pressure welding, or an
`adhesion
`layers, using pressing
`force of
`manufacturing equipment. Alternatively, the unit
`cores 6B are stacked with a resin insert in the
`insert molding member (not illustrated) including
`the resin mold and the jig. In this process, the
`resin film 17 serving as an insulator is not formed
`on both end surfaces of the yoke portion 11B of
`the unit core member 8B, and is formed over the
`angle Q defined with circumference ends of the
`yoke portion 11B and the pole shoe portion 4 at
`the inner circumference end.
`
`[0033] A flat plate member 19B that is made of a
`metal material, a non-metal material, a resin
`material, a leather material, or the like is provided
`with coupling notches 21 coupled with
`the
`protrusions 20 formed on the unit core members
`8B. A coupled portion of the unit core member
`8B is fixed with an adhesive or by welding. Coil
`conductors (not illustrated) are wound on the unit
`core members 8B. Thus, the flat plate member
`19B holds the unit core members 8B arranged in
`the annular form with b