Abstract: An overlapping portion of an insulating portion formed in an annular shape is held between a workbench having a linear projection and an ultrasonic horn having a circular projection with at least part of the linear projection and of the circular projection opposed to each other and ultrasonically welded. In the ultrasonic welding, even though the ultrasonic horn under ultrasonic vibration rotates on the overlapping portion of the insulating portion, the area in the overlapping portion held between the linear projection and the circular projection with at least part of the linear projection and of the circular projection opposed to each other is not reduced after ultrasonic vibration is applied to the ultrasonic horn.

Abstract: Annular portions of a first interphase insulting sheet have void portions. After a U-phase coil is inserted in wave winding, bridge portions are mounted to slots for an adjacent V-phase coil. The void portions are formed at positions corresponding to the bridge portions that are disposed between any two of coil ends. The annular portions are stretched to form a generally pentagon shape, which facilitates mounting of the V-phase coil. The void portions formed at positions that do not need insulation will not impair the insulating function of the first interphase insulating sheet. The void portions formed in alignment with extension of the bridge portions will not cause a drop in the strength of the annular portions.

Abstract: A motor-driven compressor includes an electric motor, a compression unit, a lead wire, a connection terminal, a cluster block, a housing, a motor drive circuit, a conductive terminal, and a coupling member. The lead wire is extended from a coil end of the stator. The connection terminal is electrically connected to the lead wire. The cluster block accommodates the connection terminal. The conductive terminal electrically connects the connection terminal and the motor drive circuit. The coupling member is arranged between the stator and the cluster block. The cluster block is coupled to the stator by the coupling member. The coupling member is configured to change an coupling position of the cluster block relative to the stator so that the connection terminal faces the conductive terminal.

Abstract: A stator core includes an insertion hole that has an opening in an outer peripheral surface of the stator core and a bent portion in the stator core. A cluster block includes an insertion piece, which is inserted into the insertion hole via the cornered portion. The cluster block is attached to the stator core by engaging the insertion piece with the insertion hole.

Abstract: A motor-driven compressor includes a compression unit, an electric motor, a motor drive circuit, a housing, and a first end plate. The electric motor includes a rotation shaft, a rotor provided with a rotor core, and a stator. The stator includes a state core and a coil. The coil includes first and second coil ends. The rotor core includes a refrigerant passage having a first opening that opens in the compression unit side. The first opening includes a first radially outer region. First and second regions in the housing are in communication through the refrigerant passage. The first end plate includes a first communication port arranged on a first region side end of the rotor core. The first region and the refrigerant passage are in communication through the first opening and first communication port. The first radially outer region is covered by the first end plate.

Abstract: A motor-driven compressor includes a compression unit having a compression chamber, a rotation shaft, an electric motor having a coil, a motor driving circuit, a housing, and a shaft support. The coil includes a first coil end, which is relatively close to the motor driving circuit, and a second coil end, which is relatively close to the compression unit. The housing includes a first area and a second area. A refrigerant passage communicates the first area with the second area. The shaft support includes a guide wall that guides the refrigerant to flow along the radial outer surface of the second coil end. The refrigerant guided by the guide wall is drawn into the compression chamber from the second area through a first suction passage. The first suction passage and the refrigerant passage are arranged at opposite sides of the rotation shaft.

Abstract: Annular portions of a first interphase insulting sheet have void portions. After a U-phase coil is inserted in wave winding, bridge portions are mounted to slots for an adjacent V-phase coil. The void portions are formed at positions corresponding to the bridge portions that are disposed between any two of coil ends. The annular portions are stretched to form a generally pentagon shape, which facilitates mounting of the V-phase coil. The void portions formed at positions that do not need insulation will not impair the insulating function of the first interphase insulating sheet. The void portions formed in alignment with extension of the bridge portions will not cause a drop in the strength of the annular portions.

Abstract: An overlapping portion of an insulating portion formed in an annular shape is held between a workbench having a linear projection and an ultrasonic horn having a circular projection with at least part of the linear projection and of the circular projection opposed to each other and ultrasonically welded. In the ultrasonic welding, even though the ultrasonic horn under ultrasonic vibration rotates on the overlapping portion of the insulating portion, the area in the overlapping portion held between the linear projection and the circular projection with at least part of the linear projection and of the circular projection opposed to each other is not reduced after ultrasonic vibration is applied to the ultrasonic horn.

Abstract: A motor-driven compressor includes a compression unit, an electric motor, a motor drive circuit, a housing, and a first end plate. The electric motor includes a rotation shaft, a rotor provided with a rotor core, and a stator. The stator includes a state core and a coil. The coil includes first and second coil ends. The rotor core includes a refrigerant passage having a first opening that opens in the compression unit side. The first opening includes a first radially outer region. First and second regions in the housing are in communication through the refrigerant passage. The first end plate includes a first communication port arranged on a first region side end of the rotor core. The first region and the refrigerant passage are in communication through the first opening and first communication port. The first radially outer region is covered by the first end plate.

Abstract: A motor-driven compressor includes an electric motor, a compression unit, a lead wire, a connection terminal, a cluster block, a housing, a motor drive circuit, a conductive terminal, and a coupling member. The lead wire is extended from a coil end of the stator. The connection terminal is electrically connected to the lead wire. The cluster block accommodates the connection terminal. The conductive terminal electrically connects the connection terminal and the motor drive circuit. The coupling member is arranged between the stator and the cluster block. The cluster block is coupled to the stator by the coupling member. The coupling member is configured to change an coupling position of the cluster block relative to the stator so that the connection terminal faces the conductive terminal.

Abstract: The permanent magnet embedded rotating electrical machine includes a rotor and a plurality of flat permanent magnets. The rotor has on an outer periphery thereof a plurality of pairs of concave portions and a plurality of convex portions. Each of the convex portions is located between the pair of concave portions. The concave portions are formed at radially outward of respective adjacent magnetic pole ends of the permanent magnet. A bridge is provided in the rotor at an angular position about an axis of the rotor between opposed magnetic pole ends of two adjacent permanent magnets. Each concave portion at radially outward of the magnetic pole end of the permanent magnet is located close to the center of the same permanent magnet in relation to the bridge next to the permanent magnet in the circumferential direction of the rotor.

Abstract: A motor-driven compressor includes a compression unit having a compression chamber, a rotation shaft, an electric motor having a coil, a motor driving circuit, a housing, and a shaft support. The coil includes a first coil end, which is relatively close to the motor driving circuit, and a second coil end, which is relatively close to the compression unit. The housing includes a first area and a second area. A refrigerant passage communicates the first area with the second area. The shaft support includes a guide wall that guides the refrigerant to flow along the radial outer surface of the second coil end. The refrigerant guided by the guide wall is drawn into the compression chamber from the second area through a first suction passage. The first suction passage and the refrigerant passage are arranged at opposite sides of the rotation shaft.

Abstract: An interphase insulative structure for a motor. The motor includes a stator core, a plurality of teeth arranged along an inner circumference of the stator core, and first to third phase windings wave wound to the stator core. The interphase insulative structure includes first interphase insulators and second interphase insulators. The first and second interphase insulators are connected between adjacent coil end conductive portions of the second winding at least at a second end of the stator core.

Abstract: A securing means for an insulating member that is advantageous in improving the efficiency of assembly of a motor-driven compressor is provided. Phase wires extending from an end face of a stator core, which is closer to a compression mechanism, are bound to form a phase wire bundle. The distal ends of the phase wires are electrically connected together, so that a wire connecting portion is formed at the distal end of the phase wire bundle. The wire connecting portion, which serves as a neutral point, is coated with an insulating tube made of insulating plastic. The distal end of the insulating tube is sealed. A receiving hole is formed in the cluster block. The insulating tube is fitted in the receiving hole and secured to the cluster block by contacting an inner surface of the receiving hole.

Abstract: A cluster block is arranged on an outer peripheral surface of a stator core. A lead wire is continuous with a U-phase coil, which extends from a coil end of the stator core, and is then connected to a U-phase connector. A lead wire is continuous with a V-phase coil, which extends from the coil end, and is then connected to a V-phase connector. A lead wire is continuous with a W-phase coil, which extends from the coil end, and is then connected to a W-phase connector. The lead wires are twisted and entwined with one another.

Abstract: A compressor includes a housing, a compression mechanism and an electric motor driving the compression mechanism. The electric motor includes a stator fixed to the housing, a rotary shaft rotatably supported by the housing, a rotor that is fixed on the rotary shaft and has a rotor core made of a plurality of laminated steel sheets, a magnet insertion hole formed through the rotor core, a permanent magnet loosely fitted in the magnet insertion hole, a first clearance formed between inner surface of the magnet insertion hole and outer surface of the permanent magnet, a second clearance formed between end surface of the rotor core and surface of the permanent magnet in the axial direction of the rotor core and resin filled in the first clearance and the second clearance so as to surround entire surface of the permanent magnet.

Abstract: A stator core includes an insertion hole that has an opening in an outer peripheral surface of the stator core and a bent portion in the stator core. A cluster block includes an insertion piece, which is inserted into the insertion hole via the cornered portion. The cluster block is attached to the stator core by engaging the insertion piece with the insertion hole.

Abstract: The motor-driven compressor includes a housing, a compression mechanism, a rotary shaft and an electric motor all disposed in the housing, a protective film and a fixing resin. The electric motor is adapted to rotate the rotary shaft thereby to drive the compression mechanism. The electric motor has a rotor fixed on the rotary shaft and a stator supported by the housing. The rotor has a permanent magnet and a magnet hole in which the permanent magnet is inserted. The magnet hole extends in an axial direction of the rotor. The protective film is formed on a surface of the permanent magnet for improving corrosion resistance of the permanent magnet. The fixing resin is filled in at least part of a gap between the permanent magnet and a wall of the magnet hole for fixing the permanent magnet to the wall of the magnet hole.

Abstract: The permanent magnet embedded rotating electrical machine includes a rotor and a plurality of flat permanent magnets. The rotor has on an outer periphery thereof a plurality of pairs of concave portions and a plurality of convex portions. Each of the convex portions is located between the pair of concave portions. The concave portions are formed at radially outward of respective adjacent magnetic pole ends of the permanent magnet. A bridge is provided in the rotor at an angular position about an axis of the rotor between opposed magnetic pole ends of two adjacent permanent magnets. Each concave portion at radially outward of the magnetic pole end of the permanent magnet is located close to the center of the same permanent magnet in relation to the bridge next to the permanent magnet in the circumferential direction of the rotor.

Abstract: An interphase insulative structure for a motor. The motor includes a stator core, a plurality of teeth arranged along an inner circumference of the stator core, and first to third phase windings wave wound to the stator core. The interphase insulative structure includes first interphase insulators and second interphase insulators. The first and second interphase insulators are connected between adjacent coil end conductive portions of the second winding at least at a second end of the stator core.