`
`
`
`
` I
`
` Jeff Bunderson, certify that I am fluent (conversant) in the Japanese and English languages, and that the
`attached English document is an accurate translation of the Japanese document attached entitled
`JPH1189128A. I understand that willful false statements and the like are punishable by fine or
`imprisonment, or both, under Section 1001 of Title 18 of the United States Code.
`
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`
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`_______________________
`Jeff Bunderson
`
`January 10, 2018
`
`
`LANGUAGE AND TECHNOLOGY SOLUTIONS FOR GLOBAL BUSINESS
`THREE PARK AVENUE, 39TH FLOOR, NEW YORK, NY 10016 | T 212.689.5555 | F 212.689.1059 | WWW.TRANSPERFECT.COM
`OFFICES IN 92 CITIES WORLDWIDE
`
`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1005-0001
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`

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`(19) Japan Patent Office (JP)
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`
`(12) Japanese Unexamined Patent
`Application Publication (A)
`
`(11) Japanese Unexamined Patent
`Application Publication Number
` Japanese Unexamined Patent
`Application Publication
`(H11-89128)
`(43) Publication date: March 30, 1999
`
`Identification codes
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`1/18
`3/46
`15/02
`15/095
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`C
`B
`G
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`(51) Int. Cl.6
`H02K
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`1/18
`3/46
`15/02
`15/095
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`(21) Application number
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`(22) Date of application
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`FI
`H02K
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`Request for examination: Not yet requested Number of claims 11 OL (Total of 6 pages)
`(71) Applicant
`000003078
`Japanese Patent
`Toshiba Corporation
`Application H9-248321
`72-banchi, Horikawa-cho, Saiwai-ku,
`
`Kawasaki-shi, Kanagawa Prefecture
`September 12, 1997
`HARUHIKO ISHIHARA
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`c/o Aichi Plant, Toshiba Corporation
`
`991-banchi, Anada-cho, Seto-shi, Aichi
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`Prefecture
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`Patent attorney NORIO ŌGO (and 1 other)
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`(72) Inventor
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`(74) Agent
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`(54) (TITLE OF THE INVENTION) STATOR FOR ELECTRIC MOTOR AND MANUFACTURING METHOD THEREOF
`
`(57) (ABSTRACT)
`(SUBJECT) A stator for an electric motor comprises a
`component with attached and immobilized magnetic pole
`teeth and coil bobbins around which coils are wound, fitted
`into an annular stator core, and the manufacturing method
`thereof; specifically, a stator for an electric motor
`assembled by connecting coil bobbins, and
`the
`manufacturing method thereof.
`(MEANS FOR SOLVING) Manufacture a coil bobbin unit 20
`that connects a predetermined number of coil bobbins 23
`by connection parts 32, and after wrapping winding wire
`22 around each coil bobbin 23, assemble the stator 24 by
`fitting and immobilizing it in a stator core 29, within which
`the coil bobbin unit 20 is given an annular shape.
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`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1005-0002
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`(2)
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`(SCOPE OF PATENT CLAIMS)
`(CLAIM 1) An electric motor stator that is characterized by
`comprising a coil; a coil bobbin unit that is [firstly] composed of
`coil bobbins that are wound with this coil and have connection
`parts, and which [secondly] allows free rotating connection with
`other coil bobbins through said connection parts; magnetic pole
`teeth that are attached to and immobilized on said coil bobbins;
`and an immobilized iron core which, through said connection
`parts, fits into and holds the annular shape formed from a
`plurality of coil bobbin units to which said magnetic pole teeth
`are attached and immobilized.
`(CLAIM 2) The electric motor stator described in Claim 1,
`characterized by having formed said connection parts in a
`structure that inlays their concave parts and convex parts in a
`rotatable manner.
`(CLAIM 3) The electric motor stator described in Claim 1,
`characterized by having formed said connection parts with
`insertion pins and insertion holes.
`(CLAIM 4) The electric motor stator described in Claim 1,
`characterized by having integrally molded said magnetic pole
`teeth and coil bobbins.
`(CLAIM 5) The electric motor stator described in Claim 1,
`characterized by having said coil bobbins divided into two
`vertically symmetrical [groups] with respect to the axial
`direction of the rotor of the electric motor.
`(CLAIM 6) The electric motor stator described in Claim 1,
`characterized by having provided
`in said coil bobbins
`protrusions and coil terminal connection parts that hold the
`connecting wire between in-phase coils.
`(CLAIM 7) The electric motor stator described in Claim 1,
`characterized in that, when said coil bobbins are formed in an
`annular shape, flange parts that close the slots between adjacent
`coil bobbins are formed on said coil bobbins.
`(CLAIM 8) The electric motor stator described in Claim 1,
`characterized by its provision of insulating dividers that link the
`connection parts of adjacent coil bobbins between said coil
`bobbins.
`(CLAIM 9) The electric motor stator described in Claim 1,
`characterized by its formation of at least one of either said coil
`bobbins or said dividers out of electric insulating material with
`high magnetic permeability.
`(CLAIM 10) Regarding the manufacturing method of an electric
`motor stator that comprises a component with attached and
`immobilized magnetic pole teeth and coil bobbins around which
`coils are wound, which is fitted into an annular stator core; a
`manufacturing method of an electric motor stator that is
`characterized by including a process to connect said coil
`bobbins in a band shape with only the predetermined number of
`connection parts, and a process to wrap winding wire around
`said coil bobbins.
`(CLAIM 11) Regarding the manufacturing method of an electric
`motor stator that comprises a component with attached and
`immobilized magnetic pole teeth and coil bobbins around which
`coils are wound, which is fitted into an iron core with an annular
`yoke; a manufacturing method of an electric motor stator that is
`characterized by including a process for said coil bobbins to
`wrap winding wire around the stator, a process to connect the
`coil bobbins through connection parts, and a process to connect
`in-phase winding wire.
`(DETAILED DESCRIPTION OF THE INVENTION)
`
`Japanese Unexamined Patent Application Publication H11-89128
`
`(0001)
`(TECHNICAL FIELD OF THE INVENTION) The present Invention
`relates to an electric motor stator and the manufacturing method
`thereof, [wherein the stator] comprises a component with
`attached and immobilized magnetic pole teeth and coil bobbins,
`formed by connecting several spools around which a coil is
`wound, which is fitted into an iron core with an annular yoke;
`specifically, it pertains to a stator for an electric motor and the
`manufacturing method thereof, which manufactures divided coil
`bobbins and connects and assembles them.
`(0002)
`(PRIOR ART) There are configurations such as the one described
`in Japanese Unexamined Patent Application Publication H7-
`245895 as an electric motor stator (stator) that uses coil bobbins.
`Namely, to explain according to Figure 10 and Figure 11, a
`stator (stator) 8 is composed of a stator core 1, a coil 4, and resin
`coil bobbins 5, while a rotor (rotor) 10 is inserted in the stator 8
`and supported in a freely rotatable manner. A plurality of coil
`bobbins 5 are successively and integrally linked in a band at
`regular intervals by thin-walled parts 15a. It is enough that the
`material of the coil bobbins 5 is insulating; they do not
`necessarily have to be made of resin.
`(0003) The manufacturing method of the stator 8 is, first of all,
`to attach magnetic pole teeth 2 to each coil bobbin 5. Although
`the magnetic pole teeth 2 are columnar, rotor-facing parts 2a are
`formed on one end in a shape that extends in a crescent. That is,
`the coil bobbins 5 are rounded into an annular shape contrary to
`the regular assembled state, by bending the thin-walled parts 15a
`so that the rotor-facing parts 2a of the magnetic pole teeth 2 that
`face the rotor 10 are on the outside; at the same time, if the
`rotor-facing parts 2a of the magnetic pole teeth 2 are
`immobilized in a position that brings them to a predetermined
`position on the winding wire member (not shown), then each
`coil bobbin 5 is connected on the side of the outer diameter and
`not on the side of the inner diameter, and thus the magnetic pole
`teeth 2 can open wide.
`(0004) In this state, [the stator] is manufactured with the
`predetermined magnetic pole teeth 2 positioned on a reference
`line to which winding wire is applied, and with winding wire
`wound normally around the coil bobbins 5 by a winding
`machine. In addition, after all coil bobbins 5 have been wound,
`they are assembled on a stator core 1 according to the
`established assembly, to manufacture the stator.
`(0005)
`In a
`INVENTION)
`(PROBLEM TO BE SOLVED BY THE
`manufacturing method such as the above for an electric motor
`stator, a plurality of coil bobbins are successively, integrally
`molded at regular intervals as a coil bobbin unit linked in a band
`by thin-walled parts, and thus manufacturability is extremely
`poor because large molding dies are required to manufacture
`this coil bobbin unit.
`(0006) Structurally as well, deformations such as displacement
`or distortion tend to occur when the coil bobbins are formed in
`an annular shape, so that it is necessary to assemble them by
`holding the coil bobbins or magnetic pole teeth with a jig.
`Furthermore, to ensure the insulation quality between the coils,
`it becomes necessary to ensure a certain spatial distance, causing
`a problem in that it becomes difficult to wind the coil with a
`high space factor.
`(0007) The present Invention was created by focusing on the
`above-noted circumstances, and its purpose is a method of good
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`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1005-0003
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`(3)
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`manufacturability, that does not require large molding dies when
`manufacturing the coil bobbin unit.
`(0008) In addition, [the purpose] is to provide an electric motor
`stator with ease of assembly because its construction does not
`produce deformations such as displacement or distortion, by
`ensuring that when the coil bobbins are formed in an annular
`shape, adjacent rotor-facing parts close the slots.
`(0009) Furthermore, [the purpose] is to provide an electric
`motor stator that decreases the spatial distance for insulation by
`providing insulating dividers between adjacent coils.
`(0010)
`(MEANS FOR SOLVING THE PROBLEM) The present invention
`provides the stator of an electric motor comprising coils , a coil
`bobbin unit comprising coil bobbins about which coils are
`wound that have connection parts, said coil bobbin units being
`able to be coupled to other coil bobbins via the aforementioned
`connection parts so as to freely pivot with them, magnetic pole
`teeth to which the aforementioned coil bobbins are fitted and
`fixed, and a fixed core to which are mated and 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
`parts.
`(0011) The present Invention is also an electric motor stator that
`is characterized by having formed said connection parts in a
`structure that inlays their concave parts and convex parts in a
`rotatable manner.
`(0012) The present Invention is also an electric motor stator that
`is characterized by having formed said connection parts with
`insertion pins and insertion holes.
`(0013) The present Invention is also an electric motor stator that
`is characterized by having integrally molded said magnetic pole
`teeth and coil bobbins.
`(0014) The present Invention is also an electric motor stator that
`is characterized by having said coil bobbins divided into two
`vertically symmetrical [groups] with respect to the axial
`direction of the rotor of the electric motor.
`(0015) The present Invention is also an electric motor stator that
`is characterized by having provided in said coil bobbins
`protrusions and coil terminal connection parts that hold the
`connecting wire between in-phase coils.
`(0016) The present Invention is also an electric motor stator that
`is characterized in that, when said coil bobbins are formed in an
`annular shape, flange parts that close the slots between adjacent
`coil bobbins are formed on said coil bobbins.
`(0017) The present Invention is an electric motor stator that is
`characterized by its provision of insulating dividers that link the
`connection parts of adjacent coil bobbins between said coil
`bobbins.
`(0018) The present Invention is also an electric motor stator that
`is characterized by its formation of at least one of either said coil
`bobbins or said dividers out of electric insulating material with
`high magnetic permeability.
`(0019) Regarding the manufacturing method of an electric
`motor stator that comprises a component with attached and
`immobilized magnetic pole teeth and coil bobbins around which
`coils are wound, which is fitted into an annular stator core; the
`present Invention is also a manufacturing method of an electric
`motor stator that is characterized by including a process to
`connect said coil bobbins in a band shape with only the
`
`
`
`Japanese Unexamined Patent Application Publication H11-89128
`
`predetermined number of connection parts, and a process to
`wrap winding wire around said coil bobbins.
`(0020) Regarding the manufacturing method of an electric
`motor stator that comprises a component with attached and
`immobilized magnetic pole teeth and coil bobbins around which
`coils are wound, which is fitted into an iron core with an annular
`yoke; the present Invention is also a manufacturing method of
`an electric motor stator that is characterized by including a
`process for said coil bobbins to wrap winding wire around the
`stator, a process to connect the coil bobbins through connection
`parts, and a process to connect in-phase winding wire.
`(0021)
`(EMBODIMENT OF THE INVENTION) The following embodiment
`of the Invention is described in reference to the drawings.
`(0022) To describe [the embodiment] according to Figure 1
`through Figure 8, typical motors are assembled with a stator and
`a rotor as shown in Figure 1 and Figure 2, as is common
`knowledge. The stator is constructed from a coil bobbin unit 20,
`which is constructed by linking multiple coil bobbins 23 to a
`stator core 29, formed by layering multiple magnetic steel sheets
`that have been punched out by a press or similar device; and [the
`stator] is constructed from magnetic pole teeth 26 that are
`attached to each coil bobbin 23. Concave parts 28 are formed on
`the inside of the ring-shaped stator core 29, in order to fit and
`immobilize the magnetic pole teeth 26. The magnetic pole teeth
`26 are formed so that a gap 34 is created between the adjacent
`rotor-facing parts 26a when the concave part 28 is fitted and
`immobilized. Naturally, the inner dimensions of the stator core
`29 are designed so that the annularly shaped coil bobbins 23 fit
`inside; meanwhile, flange parts 30 that are provided on the
`rotor-facing side of the coil bobbins 23 have been designed to
`touch the adjacent flange parts 30.
`(0023) Figure 3 illustrates the structure of each coil bobbin unit
`20 which is attached to magnetic pole teeth 26. It is the result of
`integrating the coil bobbins 23 in a band shape by connecting
`only a predetermined number of a single coil bobbin 23 or
`multiple coil bobbins 23, around which a coil 22 is wound, and
`which are connected by bendable thin-walled parts 23a, as
`shown in Figure 4, with connection parts 32. As shown in
`Figure 5 (a), the connecting part 32 has a configuration in which
`a coil bobbin 23 having a connecting portion 32a with a
`recessed profile at one end and a connecting portion 32b with a
`convex shape at the other end are mated so as to freely rotate.
`Using an engaging pin 33 and a pin hole 34 as shown in Figure
`5(b) makes a hinge, producing a structure that connects in a
`freely rotating manner. With this structure, coil bobbins 23 can
`be put in contact at will. In addition, the number of coil bobbins
`23 that are linked by the thin-walled parts 23a can be selected at
`will (this is possible as long as the number is fewer than the
`number of magnetic pole teeth 26, but taking into account
`factors such as manufacturability and the size of the molding
`dies, about two to four are adequate).
`(0024) In addition, a coil bobbin unit 20 can be formed by a
`combination of a single coil bobbin 23 and multiple integrated
`coil bobbins 23.
`(0025) Moreover, as shown in Figure 6, it is also possible to
`manufacture coil bobbins 23 by dividing them into top bobbins
`23b and bottom bobbins 23c (with respect to the axial direction
`of the rotor of the electric motor), and manufacturing them to
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`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1005-0004
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`(4)
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`be vertically symmetrical allows them to be made even
`smaller. Naturally, when winding wire, the wire is wound after
`assembling these components.
`(0026) Furthermore, in this embodiment, the coil 22 is wound
`around the coil bobbin 23 after the magnetic pole teeth 26 are
`attached, but winding around can be performed at any time,
`such as after the coil 22 is wound around [sic], or before the
`magnetic pole teeth 26 are fitted and immobilized in the stator
`core 29.
`(0027) To describe the situation of winding a coil 22 around a
`coil bobbin 23 according to Figure 7(a) and (b), first of all, the
`coil bobbin unit 20 is bent to be linear and toward the opposite
`direction from the time of assembly, widening the slots 27 that
`are between adjacent coil bobbins 23, thereby making it easier
`to wind the coil 22 inside a slot 27. In this state, the magnetic
`pole teeth 26 are aligned at regular intervals, and the in-phase
`coil 22 is subjected to successive concentrated winding around
`magnetic pole teeth 26 via a connecting wire 36. Since a
`terminal 38 and a connector are provided on the side of the
`stator core 29 of the coil bobbin 23 to connect a protrusion 37
`and coil 22 that hold the connecting wire 36, after the coil 22 is
`wound around it, the coil bobbin 23 is rounded into an annular
`shape and inserted into the stator core 29 as shown in Figure
`7(b). At that time, both ends of the coil bobbin unit 20 are
`linked and immobilized with a linking part 39, provided in
`advance.
`(0028) Furthermore, when rounding into an annular shape, the
`slots 27 that were widened when winding the coil 22 can be
`closed by means of adjacent coil bobbins 23, the thin-walled
`parts 23a, and the flange parts 30 (however, in terms of the
`magnetic circuit, it is equivalent to an open magnetic circuit or
`a semi-open magnetic circuit). By this means, the coil bobbins
`23 become linked and immobilized on the inner diameter and
`the outer diameter, making it unlikely for deformations such as
`distortion to occur, and making it easier to insert them into the
`stator core 29.
`(0029) In addition, as shown in Figure 8, providing dividers 40
`that insulate between the coils 22 and that take on the
`additional function of connection parts between the coil
`bobbins 23 means that there is no longer any need to set aside
`spatial distance to ensure insulation quality between the coils
`22, allowing even more of the coil 22 to be wound, and
`improving the space factor.
`(0030) Additionally, the material of the coil bobbins 23 is not
`limited to resin; any material can be used as long as it has high
`insulation properties, but by using insulating material with high
`magnetic permeability (e.g., plastic magnet or material that
`combines resin with iron oxide) for all of the coil bobbins 23 or
`for the dividers 40, the dividers 40 can be reused as auxiliary
`salient poles of the stator 24, reducing torque ripple and
`cogging torque.
`(0031) Furthermore, after winding the coil 22 around the coil
`bobbins 23, it can also link the coil bobbins 23 in a band shape.
`That is, as shown in Figure 9, after attaching magnetic pole
`teeth 26 to a coil bobbin 23, the coil 22 can also be wound
`around [them]. In such a case, it would be advisable to provide
`a terminal 38 to connect (immobilize) the winding start and the
`winding end of the coil 22 around the coil bobbin 23, so that it
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`Japanese Unexamined Patent Application Publication H11-89128
`
`is easier to connect between the coils 22. After the coil bobbins
`23 are linked in a band shape, the coil bobbin unit 20 is
`rounded into an annular shape, and the outside of the magnetic
`pole teeth 26 is fitted into the concave parts 28 inside the stator
`core 29 to immobilize it, in the same way as the embodiment
`previously described.
`(0032) Moreover, it need scarcely be mentioned that a variety
`of additional modified implementations are available that do
`not deviate from the intent of the present Invention.
`(0033)
`(EFFECT OF THE INVENTION) Because the present Invention
`enables a coil bobbin unit to be assembled in connection with a
`predetermined number of coil bobbins as needed, it can be
`manufactured with
`compact molding dies,
`rendering
`unnecessary the large molds required to integrally mold a coil
`bobbin unit of the conventional variety; moreover, even if there
`is low quality in the yield, the parts can be interchanged.
`(0034) Because the present Invention also changes the coil
`bobbin connection parts so that they freely rotate, the gaps
`between adjacent coil bobbins can be made wider when
`winding the coil around the coil bobbin, and their condition can
`be configured at will; therefore, winding the coil becomes
`extremely easy, and the coil space factor can be increased.
`(0035) Because the present Invention also has the coil bobbins
`and magnetic pole teeth integrally molded, assembly becomes
`easy, and assembly precision can be improved.
`(0036) Because the present Invention has also divided the coil
`bobbins into two vertically symmetrical [groups] with respect
`to the axial direction of the electric motor, their molding dies
`can be made more compact.
`(0037) Because the present Invention has also provided
`protrusions and coil terminal connection parts to hold the
`connecting wire of in-phase coils in the stator core, the ease of
`assembly can be improved for the stator.
`(0038) Because the present Invention also provides flange parts
`on the coil bobbins, the slots can be closed by the flange parts
`on adjacent coil bobbins when shaping the coil bobbin unit into
`a circle, which has vastly improved the ease of assembly of the
`stator.
`(0039) Because the present Invention also provides dividers
`that insulate between the coils between coil bobbins, these can
`reduce the insulation space and also be used as auxiliary salient
`poles for the stator.
`(0040) Because the manufacturing method of the electric motor
`stator under the present Invention [uses] a winding wire that
`links a predetermined number of coil bobbins in a band shape,
`winding the coil becomes extremely easy, and handling the
`connecting wire becomes easier[.] In addition, the coil space
`factor can be increased, and the manufacturing costs of the
`stator and electric motor can be reduced.
`(0041) Because the manufacturing method of the electric motor
`stator under the present Invention connects the coil bobbins
`when the winding wire has been wound around them, the
`electric motor stator can be assembled easily.
`(BRIEF DESCRIPTION OF THE DRAWINGS)
`(FIGURE 1) Top view of the principal parts of the electric motor
`stator according to the embodiment of the Invention
`
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`Am. Honda v. IV II - IPR2018-00619
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`(FIGURE 2) Horizontal view of the principal parts of the electric
`motor stator according to the embodiment of the Invention
`(FIGURE 3) Side view of the Invention’s coil bobbins, etc.,
`connected
`(FIGURE 4) Side view of the Invention’s coil bobbins
`(FIGURE 5) Perspective view showing a connection part
`(FIGURE 6) Perspective view dividing the coil bobbins into two
`(FIGURE 7) (a) is a side view with the coil bobbins connected
`and the connecting wire laid out; (b) is a top view of the coil
`bobbin unit linked in an annular shape.
`(FIGURE 8) (a) is a side view of dividers provided where coil
`bobbins are connected; (b) is a top and side view of the
`dividers.
`(FIGURE 9) Side view to explain the embodiment in which [the
`stator] is assembled by connecting the coil bobbins in a band
`shape after winding the coil around the coil bobbins
`(FIGURE 10) Top view of a conventional electric motor stator
`(FIGURE 11) To explain the attachment of the conventional coil
`bobbin tight magnetic pole teeth, (a) is a side view showing the
`condition before attaching the two, and (b) is a side view
`showing
`the condition when
`the
`two are attached.
`
`
`
`Japanese Unexamined Patent Application Publication H11-89128
`
`(EXPLANATION OF REFERENCES)
`20… Coil bobbin unit
`22… Coil
`23… Coil bobbin
`24… Stator (stator)
`25… Rotor (rotor)
`26… Magnetic pole teeth (Magnetic pole teeth)
`27… Slot
`28… Concave part
`29… Stator core
`23a… Thin-walled part
`32… Connection part
`33… Engaging pin
`34… Pin hole
`36… Connecting wire
`37… Protrusion
`38… Terminal
`39… Linking part
`40… Divider
`
`
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`(FIGURE 1)
`
`(FIGURE 2)
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`(FIGURE 4)
`
`(FIGURE 6)
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`(FIGURE 3)
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`(FIGURE 5)
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`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1005-0006
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`Japanese Unexamined Patent Application Publication H11-89128
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`(FIGURE 7)
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`(FIGURE 8)
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`(FIGURE 9)
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`(FIGURE 10)
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`(FIGURE 11)
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`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1005-0007
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`Am. Honda V. IV 11 - IPR2018-00619
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`PET_HONDA_1005—0008
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`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1005-0008
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`PET_HONDA_1005—0009
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`Am. Honda v. IV II - IPR2018-00619
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`

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