Core components, motors, compressors and vehicles

Abstract

The present invention provides a core assembly, a motor, a compressor, and a vehicle. The core assembly includes: a core body, the core body includes a plurality of segmented cores, and a mounting groove is provided at the edge of at least one end face of each segmented core; a plurality of insulating frames, each segmented core is arranged between two insulating frames, and the two insulating frames are distributed at both ends of a segmented core, and at least one insulating frame is provided with an insulating protrusion for covering both sides of the segmented core on one end face facing the segmented core, and the insulating protrusion cooperates with the mounting groove. By covering both sides of the segmented core with the insulating protrusion, the thickness of the portion of the insulating frame covering the end face of the segmented core and extending along the end face can be effectively reduced while ensuring sufficient creepage distance between the winding of the motor and the core assembly, thereby reducing the length of the core assembly in the axial direction of the core body, thereby facilitating reduction in motor volume and weight, and high insulation reliability.

Description

Technical Field

[0001] The present invention belongs to the technical field of motors, and in particular, relates to an iron core assembly, a motor, a compressor, and a vehicle including the compressor. Background Art

[0002] In the motor industry, miniaturization and lightweighting play a crucial role in reducing product costs and power consumption, and are therefore a key area of ​​ongoing research within the industry. The automotive industry, in particular, often utilizes smaller and lighter motors with a segmented stator core structure and concentrated windings (referred to as "segmented motors") to reduce vehicle weight. These motors are used in applications such as electric power steering (EPS) motors, water pump motors, main drive motors, and compressor motors.

[0003] In order to reduce the power consumption of the segmented motor, the utilization rate of the motor winding slot is usually increased, and electromagnetic wire with a larger conductor diameter is wound in. Some segmented motors use a three-section insulation structure, which is composed of an insulating skeleton assembled at both ends of the segmented iron core and slot insulation paper installed in the winding slot. In order to ensure that there is sufficient creepage distance between the iron core and the electromagnetic wire, especially for motors with higher operating voltages, this insulation structure usually requires the insulating skeleton to be set on the end face of the segmented iron core and the thickness of this part extending along the end face is set to be thicker. However, this will cause the axial height of the stator to increase and the volume to increase. And because the winding is wound on the insulating skeleton, the circumference of the winding coil will also increase, resulting in an increase in motor resistance and reduced energy efficiency. Summary of the Invention

[0004] The present invention aims to solve one of the technical problems existing in the prior art or related art.

[0005] To this end, a first aspect of the present invention provides a core assembly.

[0006] A second aspect of the present invention provides an electric motor.

[0007] A third aspect of the present invention provides a compressor.

[0008] A fourth aspect of the present invention provides a vehicle.

[0009] In view of this, according to the first aspect of the present invention, a core assembly is proposed, including: a core body, the core body including a plurality of segmented cores, and a mounting groove is provided at the edge of at least one end face of each segmented core; a plurality of insulating frames, each segmented core is arranged between two insulating frames, and is distributed in the two insulating frames at both ends of a segmented core, and at least one insulating frame has an insulating protrusion on one end face facing the segmented core for covering both sides of the segmented core, and the insulating protrusion cooperates with the mounting groove.

[0010] The core assembly provided by the present invention comprises a core body and multiple insulating frames. The core body comprises multiple segmented cores, which can be continuously distributed to form a ring-shaped core body. Each segmented core is positioned between two insulating frames, and mounting slots are provided at the edge of at least one end face of each segmented core. Insulating protrusions are provided on the end faces of the two insulating frames located at both ends of a segmented core, the insulating frames located near the mounting slots facing the segmented cores. The insulating protrusions are then wrapped around both sides of the segmented cores, and the insulating protrusions are adapted to engage with the mounting slots. On the one hand, because the insulating protrusions are wrapped around both sides of the segmented core, it can effectively reduce the thickness of the portion of the insulating skeleton that is provided on the end face of the segmented core and extends along the end face while ensuring sufficient creepage distance between the winding and the core assembly of the motor. This portion is hereinafter referred to as the end of the insulating skeleton. Compared with the related art in which the thickness of the end of the insulating skeleton has to be increased to ensure creepage distance between the winding and the core, the reduction in thickness of the end of the insulating skeleton greatly reduces the length of the core assembly in the axial direction of the core body, thereby facilitating reduction in motor volume and weight, and high insulation reliability. Moreover, due to the reduction in thickness of the end of the insulating skeleton, the axial length of the electromagnetic wire wound around the segmented core will also be reduced, thereby reducing the amount of electromagnetic wire used and reducing costs. On the other hand, because the insulating protrusions cooperate with the mounting slots, the provision of the insulating protrusions does not occupy the space of the winding slots, thereby improving the utilization rate of the winding slots and further facilitating reduction in motor volume and weight.

[0011] Specifically, in the related art, the insulating skeleton is not covered on both sides of the segmented core, but is directly covered on the end face of the segmented core. In this case, the creepage distance between the winding and the core assembly mainly depends on the thickness of the end of the insulating skeleton. In order to meet the creepage distance requirements, the thickness of the end of the insulating skeleton has to be set thicker. Moreover, since the insulating skeleton is distributed at both ends of the segmented core, the overall height of the core assembly is further increased, that is, the length of the core assembly in the axial direction of the core body. However, the present application provides a mounting groove on the segmented core, and the insulating protrusion on the insulating skeleton covers the segmented core and is inserted into the mounting groove. In this case, the creepage distance between the winding and the core assembly mainly depends on the sum of the depth of the mounting groove in the axial direction of the core body and the height of the protrusion in the axial direction of the core body. Therefore, the thickness of the end of the insulating skeleton can be significantly reduced, greatly reducing the volume of the core assembly.

[0012] Optionally, mounting grooves are provided at the edges of both end faces of each segmented iron core, and insulating protrusions are also provided on the two insulating frames distributed at both ends of a segmented iron core, which can reduce the thickness of the ends of the two insulating frames at both ends of the segmented iron core, greatly reducing the length of the iron core assembly in the axial direction of the iron core body, thereby helping to reduce the volume of the motor.

[0013] Optionally, the insulating protrusions are integrally formed with the insulating frame. The insulating frame can be a whole frame structure, or can be composed of a frame structure and an insulating layer filled on the frame structure.

[0014] Among them, it should be noted that, in the present application, the edge of the end face of the segmented iron core is provided with a mounting groove, which means that the mounting groove is opened on the end face of the segmented iron core, and the mounting groove extends to the edge of the end face of the segmented iron core, that is, the mounting groove has only one groove side wall in its width direction. Here, it is assumed that the direction in which the mounting groove extends toward the edge is the width direction of the mounting groove, and the direction in which the mounting groove extends along the edge is the length direction of the mounting groove. The width direction and length direction of each part of the mounting groove change with the change of the edge. In addition, the insulating protrusion is coated on both sides of the segmented iron core, and can be coated on both sides of the entire segmented iron core, or on both sides of a portion of the segmented iron core. The edge of the end face of the segmented iron core is provided with a mounting groove, and the edge is provided with a mounting groove, as long as it meets the requirements of matching with the insulating protrusion.

[0015] In addition, the core assembly in the above technical solution provided by the present invention may also have the following additional technical features:

[0016] In the above technical solution, preferably, the segmented iron core includes a yoke portion, a tooth portion and a pole shoe portion, and the insulating protrusion is at least covered on both sides of the tooth portion and the pole shoe portion.

[0017] In this technical solution, the segmented core can be constructed from multiple stacked and riveted laminations. The segmented core includes a yoke, teeth, and pole shoes, with the teeth located between the yoke and pole shoes. By providing insulating protrusions covering at least both sides of the teeth and pole shoes, sufficient creepage distance is ensured between the winding and the core assembly, ensuring the insulation reliability of the core assembly.

[0018] In any of the above technical solutions, preferably, the insulating protrusion is also covered on a side of the yoke facing the tooth portion.

[0019] In this technical solution, by also covering the side of the yoke facing the teeth, the insulating protrusion helps to ensure sufficient creepage distance between the winding and the core assembly, further improving the insulation reliability of the core assembly. The insulating protrusion can completely cover the side of the yoke facing the teeth, or it can partially cover the side of the yoke facing the teeth, and the setting can be adjusted accordingly.

[0020] In any of the above technical solutions, preferably, two adjacent mounting grooves on two adjacent segmented cores are in contact and connected.

[0021] In this technical solution, any two adjacent segmented iron cores are enclosed to form a winding slot, and the electromagnetic wire can be distributed in the winding slot and wound on the segmented iron core with an insulating skeleton and slot insulation paper to form a winding. By setting the two adjacent mounting slots on the two adjacent segmented iron cores to be in contact and connected to each other. At this time, the two connected mounting slots can be continuously distributed at the notch of the winding slot. On the one hand, it provides sufficient space for the insertion of the insulating protrusion, which is conducive to the insulating protrusion covering more of the segmented iron core and improving the insulation effect. On the other hand, it facilitates the processing of the mounting slot to avoid processing errors that affect the operation effect of the motor.

[0022] Of course, when multiple segmented cores are continuously distributed, two adjacent mounting grooves on two adjacent segmented cores may not touch or communicate with each other. In this case, the end of the mounting groove away from the pole shoe portion has a groove sidewall, which is conducive to improving the installation stability of the insulating protrusion.

[0023] In any of the above technical solutions, preferably, the depth L1 of the mounting groove in the axial direction of the core body and the height H1 of the insulating protrusion in the axial direction of the core body satisfy H1≤L1.

[0024] In this technical solution, by setting the depth L1 of the mounting groove in the axial direction of the core body to be greater than or equal to the height H1 of the edge protrusion in the axial direction of the core body, assembly interference between the insulating frame and the segmented core can be effectively avoided.

[0025] In any of the above technical solutions, preferably, the maximum magnetic density T1 of the teeth of the segmented iron core covered by the insulating protrusions, the maximum magnetic density T2 of the teeth of the segmented iron core not covered by the insulating protrusions, the width D1 of the mounting groove on a cross section of the core body, and the width D2 of the teeth of the segmented iron core not covered by the insulating protrusions satisfy D1≤D2(T1-T2) / T1.

[0026] In this technical solution, since the present application sets the mounting grooves at the edges of the two end faces of the segmented core, the width of the teeth and / or yoke of the segmented core in the end region will be narrowed. Since the yoke and teeth of the segmented core are both the magnetic circuit of the motor, the narrowing of the width of the teeth and yoke in the end region will cause the magnetic density of the segmented core to increase and the iron loss to increase, especially the impact on the teeth. Therefore, in order to reduce the above-mentioned impact on the motor loss, the maximum width D1 of the mounting groove on a cross section of the core body is set to satisfy the following relationship: D2(T1-T2) / T1, wherein D2 is the width of the effective area of ​​the teeth of the segmented core, that is, the width of the teeth of the segmented core not covered by the insulating protrusion, T1 is the maximum magnetic density of the teeth of the segmented core covered by the insulating protrusion, and T2 is the maximum magnetic density of the teeth of the segmented core not covered by the insulating protrusion. The magnetic density is the magnetic flux density, which can effectively prevent the magnetic flux density of the teeth from exceeding the working saturation point, causing a sharp increase in iron loss.

[0027] Among them, the maximum magnetic density of the teeth of the segmented iron core covered by the insulating protrusions and the maximum magnetic density of the teeth of the segmented iron core not covered by the insulating protrusions, that is, the maximum magnetic flux density, are set according to the motor speed and motor load, and can also be set according to the material of the segmented iron core and / or the required motor efficiency. Specifically, when the material of the punching sheets constituting the segmented iron core is silicon steel plate, the maximum magnetic flux density of the teeth of the segmented iron core covered by the insulating protrusions can be set to 2.0T (wherein T is the unit of magnetic flux density, Tesla). Since the magnetic flux density of the teeth of the segmented iron core is generally 1.6T to 1.8T in the related art, the maximum magnetic flux density of the teeth of the segmented iron core not covered by the insulating protrusions can be set to 1.6T, and then the relationship between D1 and D2 can be: D1≤D2(2.0T-1.6T) / 2.0T.

[0028] In any of the above technical solutions, preferably, a width D1 of the mounting groove on a cross section of the core body and a width D2 of the tooth portion of the segmented core not covered by the insulating protrusion satisfy D1≤0.2D2.

[0029] In this technical solution, by setting the width D1 of the mounting groove on a cross section of the core body to be less than or equal to 0.2 times the width D2 of the teeth of the segmented core not covered by the insulating protrusion, it is possible to effectively avoid the width of the teeth and / or yoke of the segmented core from becoming excessively narrowed in the end area, which would lead to an excessive increase in the magnetic flux density of the segmented core, especially an excessive increase in the magnetic flux density of the teeth of the segmented core, resulting in a sharp increase in iron loss. In particular, when the material of the punching sheets constituting the segmented core is silicon steel plate, it is suitable for a variety of motor speeds and a variety of motor loads, and meets a variety of required motor efficiencies. For example, the maximum magnetic flux density of the teeth of the segmented core covered by the insulating protrusion can be 1.8T or 1.8T or 1.3T, etc., and the corresponding maximum magnetic flux density of the teeth of the segmented core not covered by the insulating protrusion can be 1.5T or 1.7T or 1.1T, etc., which are not listed here one by one.

[0030] In any of the above technical solutions, preferably, a width D1 of the mounting groove on a cross section of the core body and a width D2 of the tooth portion of the segmented core not covered by the insulating protrusion satisfy 0.05D2≤D1.

[0031] In this technical solution, by setting the width D1 of the mounting slot on a cross-section of the core body to be greater than or equal to 0.05 times the width D2 of the teeth of the segmented core not covered by the insulating protrusion, this not only helps ensure that the mounting slot is wide enough to facilitate the insertion of the insulating protrusion, but also facilitates the insertion of a sufficiently thick insulating protrusion into the mounting slot, thereby improving the insulation performance of the core assembly. In particular, when the insulating protrusion is integrally injection-molded with the insulating framework, this avoids requiring the insulating protrusion to be excessively thin to be inserted into the mounting slot, facilitating the processing of the insulating protrusion. The value of 0.05 was determined after multiple experiments, taking into account the above factors.

[0032] In any of the above technical solutions, preferably, the width D1 of the mounting groove on a cross section of the segmented core is the same or not completely the same everywhere.

[0033] In any of the above technical solutions, preferably, the core assembly further comprises: an insulating member, which is arranged in a winding slot formed by two adjacent segmented cores.

[0034] In this technical solution, the insulation of the core assembly is ensured by arranging an insulating member in a winding slot formed by two adjacent segmented cores.

[0035] In any of the above technical solutions, preferably, the insulating member is constructed by the portion of the insulating frame extending into the winding slot. That is, in addition to the insulating protrusion, the insulating frame also has an insulating portion extending into the winding slot for insulation, and the insulating portion covers the sidewalls of the winding slot.

[0036] In any of the above technical solutions, preferably, the insulating member is slot insulation paper. Furthermore, the slot insulation paper includes two extensions, the two extensions being located at both ends of the slot insulation paper along the axial direction of the core body, each extension extending along the axial direction of the core body, and being located in the gap between two adjacent insulation frames.

[0037] This technical solution uses slot insulation paper installed within the winding slots for insulation. Compared to the previous insulation method where an insulating frame is installed at each end of the segmented core and extends into the winding slots, the insulating frame is typically manufactured using an injection molding process and then installed in conjunction with the winding slots. The portion of the insulating frame that extends into the winding slots is relatively thick, occupying a large area of ​​the winding slots. However, this solution, by installing slot insulation paper within the winding slots, can maintain insulation effectiveness while reducing the space occupied by the winding slots, thereby ensuring winding slot utilization.

[0038] In addition, since the insulating skeletons corresponding to the segmented cores are also arranged in segments, there will be a gap between the two adjacent insulating skeletons on the two adjacent segmented cores. While the thickness of the insulating skeleton ends is reduced, the height of the slot insulating paper that matches it in the axial direction of the core body is also reduced. Therefore, by arranging slot insulating paper in the winding slot and setting the protruding parts of the slot insulating paper at both ends along the axial direction of the core body to be located in the gap between the two adjacent insulating skeletons, the gap between the two adjacent insulating skeletons is blocked, which can compensate for the insufficient creepage distance between the gap between the adjacent insulating skeletons and the segmented cores caused by the reduced thickness of the insulating skeleton ends. The creepage distance can be increased to ensure that the creepage distance between the core assembly and the winding at the gap is sufficient, thereby ensuring the insulation reliability of the core assembly.

[0039] In any of the above technical solutions, preferably, the length H2 of the protruding portion extending in the axial direction of the core body and the height H1 of the insulating protrusion in the axial direction of the core body satisfy H2≥H1.

[0040] In this technical solution, by setting the length H2 of the protruding portion extending axially along the core body to be greater than or equal to the height H1 of the insulating protrusion in the axial direction of the core body, it is beneficial to compensate for sufficient creepage distance so that the creepage distance meets the national standard or the customer's insulation safety requirements for the product.

[0041] In any of the above technical solutions, preferably, the material of the insulating frame is liquid crystal polymer containing glass fiber or polybutylene terephthalate containing glass fiber.

[0042] In this technical solution, by setting the material of the insulating skeleton to liquid crystal polymer (LCP) containing glass fiber or polybutylene terephthalate (PBT) containing glass fiber, the insulating effect is good.

[0043] In any of the above technical solutions, preferably, the slot insulation paper is made of polyethylene terephthalate plastic, polyethylene naphthalate, or polyphenylene sulfide.

[0044] In this technical solution, by setting the material of the slot insulation paper to polyethylene terephthalate plastic (PET) or polyethylene naphthalate (PEN) or polyphenylene sulfide (PPS), the insulation effect is good and it is not easy to be damaged.

[0045] A second aspect of the present invention provides a motor, comprising: an iron core assembly as described in any one of the above technical solutions.

[0046] The motor provided by the present invention, by virtue of comprising the core assembly of any of the above-described technical solutions, thereby exhibiting the beneficial effects of any of the above-described technical solutions, will not be described in detail here. The motor includes a stator and a rotor. Optionally, the stator includes windings and the core assembly of any of the above-described technical solutions. In this case, the winding slots are stator slots. Of course, the rotor may also include the core assembly of any of the above-described technical solutions, with the winding slots being rotor slots.

[0047] The electric motor is preferably a rotary electric motor.

[0048] A third aspect of the present invention provides a compressor, comprising: a motor as described in any one of the above technical solutions.

[0049] The compressor provided by the present invention has the motor of any one of the above technical solutions, and thus has the beneficial effects of any of the above technical solutions, which will not be described in detail here.

[0050] A fourth aspect of the present invention provides a vehicle, comprising: a compressor as described in any one of the above technical solutions.

[0051] The vehicle provided by the present invention has the compressor of any one of the above technical solutions, and thus has the beneficial effects of any of the above technical solutions, which will not be described in detail here.

[0052] Additional aspects and advantages of the invention will become apparent from the description which follows, or may be learned by practice of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the following description of the embodiments with reference to the accompanying drawings, in which:

[0054] Figure 1 A partial cross-sectional schematic diagram of the block core and the insulating frame after unfolding in the related art is shown;

[0055] Figure 2 A schematic diagram of the partial structure of the segmented iron core and the insulating frame after unfolding according to an embodiment of the present invention is shown;

[0056] Figure 3 A schematic diagram of the three-dimensional structure of the segmented iron core and the insulating frame after unfolding according to an embodiment of the present invention is shown;

[0057] Figure 4 A schematic structural diagram of a segmented core according to an embodiment of the present invention is shown;

[0058] Figure 5 A schematic diagram of a top view of a segmented core according to an embodiment of the present invention is shown;

[0059] Figure 6A schematic structural diagram of an insulating skeleton according to an embodiment of the present invention is shown;

[0060] Figure 7 A schematic structural diagram of slot insulation paper according to an embodiment of the present invention is shown;

[0061] Figure 8 A schematic diagram of a disassembled core assembly according to an embodiment of the present invention is shown;

[0062] Figure 9 A schematic structural diagram of an iron core assembly according to an embodiment of the present invention is shown;

[0063] in, Figure 1 The corresponding relationship between the reference numerals and component names is as follows:

[0064] 12' segmented iron core, 14' insulating frame, 144' end of the insulating frame;

[0065] Figures 2 to 9 The corresponding relationship between the reference numerals and component names is as follows:

[0066] 10 core assembly, 12 segmented core, 122 mounting slot, 124 yoke, 126 tooth, 128 pole shoe, 14 insulating frame, 142 insulating protrusion, 144 end of insulating frame, 16 winding slot, 18 slot insulating paper, 182 extension. DETAILED DESCRIPTION

[0067] In order to more clearly understand the above-mentioned objects, features and advantages of the present invention, the present invention is further described in detail below in conjunction with the accompanying drawings and specific embodiments. It should be noted that, in the absence of conflict, the embodiments of the present application and the features therein can be combined with each other.

[0068] In the following description, many specific details are set forth to facilitate a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Therefore, the scope of protection of the present invention is not limited to the specific embodiments disclosed below.

[0069] Refer to the following Figures 1 to 9 The core assembly 10 , the motor, and the compressor according to some embodiments of the present invention are described.

[0070] like Figures 2 to 6As shown, an embodiment of the first aspect of the present invention proposes an iron core assembly 10, comprising: an iron core body, the iron core body comprising a plurality of segmented iron cores 12, and an installation groove 122 is provided at the edge of at least one end face of each segmented iron core 12; a plurality of insulating frames 14, each segmented iron core 12 is arranged between two insulating frames 14, and is distributed in the two insulating frames 14 at both ends of a segmented iron core 12, and there is at least one insulating frame 14 with an insulating protrusion 142 for covering both sides of the segmented iron core 12 on one end face facing the segmented iron core 12, and the insulating protrusion 142 cooperates with the installation groove 122.

[0071] The core assembly 10 provided by the present invention includes a core body and a plurality of insulating frames 14. Figure 9 As shown, the core body includes multiple segmented cores 12, which are continuously distributed to form a ring-shaped core body. Each segmented core 12 is positioned between two insulating frames 14, and a mounting groove 122 is provided at the edge of at least one end face of each segmented core 12. An insulating protrusion 142 is provided on an end face of the insulating frame 14 facing the segmented core 12, adjacent to the mounting groove 122. The insulating protrusion 142 covers both sides of the segmented core 12 and engages with the mounting groove 122. On the one hand, because the insulating protrusions 142 are wrapped around both sides of the segmented core 12, while ensuring sufficient creepage distance between the motor winding and the core assembly 10, the thickness of the portion of the insulating frame 14 that covers and extends along the end face of the segmented core 12 can be effectively reduced. This portion is hereinafter referred to as the end 144 of the insulating frame 14. Compared with the related art, which has to increase the thickness of the end 144' of the insulating frame 14' to ensure creepage distance between the winding and the core, the reduction in the thickness of the end 144 of the insulating frame 14 greatly reduces the axial length of the core assembly 10 in the core body, thereby facilitating a reduction in the size and weight of the motor and providing high insulation reliability. Moreover, due to the reduced thickness of the end 144 of the insulating frame 14, the axial length of the electromagnetic wire wound around the segmented core 12 is also reduced, thereby reducing the amount of electromagnetic wire used and reducing costs. On the other hand, since the insulating protrusion 142 cooperates with the mounting groove 122, the setting of the insulating protrusion 142 does not occupy the space of the winding groove 16. While improving the utilization rate of the winding groove 16, it is further beneficial to reduce the volume and weight of the motor.

[0072] Specifically, in the related art, Figure 1As shown, the insulating frame 14' does not cover both sides of the segmented core 12', but is directly covered on the end face of the segmented core 12'. In this case, the creepage distance between the winding and the core assembly is mainly determined by the thickness of the end 144' of the insulating frame 14', that is, L1' + L2'. To meet the creepage distance requirements, the thickness of the end 144' of the insulating frame 14' must be set thicker. Moreover, because the insulating frame 14' is distributed at both ends of the segmented core 12', the overall height of the core assembly is further increased, that is, the length of the core assembly in the axial direction of the core body. Similarly, the increase in the thickness of the end 144' of the insulating frame 14' also increases the winding length of the winding in the axial direction of the core body, which is the length of the segmented core 12' P' + 2 (L1' + L2'). The present application provides a mounting groove 122 on the segmented iron core 12, and the insulating protrusion 142 on the insulating frame 14 covers the segmented iron core 12 and is inserted into the mounting groove 122. Figure 2 As shown, the creepage distance between the winding and the core assembly 10 is primarily determined by the sum of the depth L1 of the mounting slot 122 in the axial direction of the core body and the thickness L2 of the end portion 144 of the insulating frame 14. Consequently, the thickness of the end portion 144 of the insulating frame 14 can be significantly reduced, significantly reducing the volume of the core assembly 10. Furthermore, the winding length of the winding in the axial direction of the core body is also reduced, becoming the length P of the segmented core 12 + 2 × L2, which is twice the length L1, significantly reducing the volume of the core assembly 10.

[0073] Optionally, mounting grooves 122 are provided at the edges of both end surfaces of each segmented iron core 12, and insulating protrusions 142 are also provided on the two insulating frames 14 distributed at both ends of a segmented iron core 12, which can reduce the thickness of the ends 144 of the two insulating frames 14 at both ends of the segmented iron core 12, greatly reducing the length of the core assembly 10 in the axial direction of the core body, thereby helping to reduce the volume of the motor.

[0074] Optionally, the insulating protrusions 142 are integrally formed with the insulating frame 14. The insulating frame 14 can be a single, integral frame structure, or can be composed of a frame structure and an insulating layer subsequently filled thereon. When the insulating protrusions 142 are integrally formed with the insulating frame 14, the insulating frame 14 is equivalent to being partially embedded in the segmented core 12.

[0075] It should be noted that, in the present application, the edge of the end face of the segmented core 12 is provided with a mounting groove 122, which means that the mounting groove 122 is opened on the end face of the segmented core 12, and the mounting groove 122 extends to the edge of the end face of the segmented core 12, that is, the mounting groove 122 has only one groove side wall in its width direction. Here, it is assumed that the direction in which the mounting groove 122 extends toward the edge is the width direction of the mounting groove 122, and the direction in which the mounting groove 122 extends along the edge is the length direction of the mounting groove 122. The width direction and length direction of each part of the mounting groove 122 change with the change of the edge. In addition, the insulating protrusion 142 is coated on both sides of the segmented core 12, and can be coated on both sides of the entire segmented core 12, or on both sides of a portion of the segmented core 12. The mounting groove 122 is provided at the edge of the end face of the segmented core 12, or the mounting groove 122 is provided at a portion of the edge, as long as it satisfies the requirements of matching with the insulating protrusion 142.

[0076] In some embodiments, as Figures 4 to 6 As shown, the segmented core 12 includes a yoke portion 124 , a tooth portion 126 and a pole shoe portion 128 , and the insulating protrusion 142 at least covers both sides of the tooth portion 126 and the pole shoe portion 128 .

[0077] In this embodiment, the segmented core 12 is formed by riveting a plurality of punching sheets together. The segmented core 12 includes a yoke 124, a tooth 126, and a pole shoe 128. The tooth 126 is located between the yoke 124 and the pole shoe 128. By providing the insulating protrusion 142 to cover at least both sides of the tooth 126 and the pole shoe 128, a sufficient creepage distance is ensured between the winding and the core assembly 10, thereby ensuring the insulation reliability of the core assembly 10.

[0078] In some embodiments, as Figures 4 to 6 As shown, the insulating protrusion 142 also covers the side of the yoke 124 facing the teeth 126 .

[0079] In this embodiment, the insulating protrusion 142 also covers the side of the yoke 124 facing the teeth 126, which helps to ensure a sufficient creepage distance between the winding and the core assembly 10, further improving the insulation reliability of the core assembly 10. The insulating protrusion 142 can completely cover the side of the yoke 124 facing the teeth 126, or can partially cover the side of the yoke 124 facing the teeth 126, and can be set accordingly according to actual conditions.

[0080] In some embodiments, as Figure 8 As shown, two adjacent mounting grooves 122 on two adjacent segmented cores 12 are in contact and connected.

[0081] In this embodiment, any two adjacent segmented cores 12 are enclosed to form a winding groove 16, and the electromagnetic wire can be distributed in the winding groove 16 and wound on the segmented core 12 with the insulating skeleton 14 and the slot insulating paper 18 to form a winding. By setting the two adjacent mounting grooves 122 on the two adjacent segmented cores 12 to be in contact and connected to each other. At this time, the two connected mounting grooves 122 can be continuously distributed at the notch of the winding groove 16. On the one hand, sufficient space is provided for the insertion of the insulating protrusion 142, which is conducive to the insulating protrusion 142 to cover more of the segmented core 12 and improve the insulation effect. On the other hand, it is convenient for the processing of the mounting groove 122 to avoid processing errors that affect the operation effect of the motor.

[0082] Of course, when multiple segmented cores 12 are continuously distributed, two adjacent mounting grooves 122 on two adjacent segmented cores 12 may not touch or communicate with each other. In this case, the end of the mounting groove 122 away from the pole shoe portion 128 has a groove sidewall, which helps to improve the installation stability of the insulating protrusion 142.

[0083] In some embodiments, as Figure 2 and Figure 6 As shown, the depth L1 of the mounting groove 122 in the axial direction of the core body and the height H1 of the insulating protrusion 142 in the axial direction of the core body satisfy H1≤L1.

[0084] In this embodiment, by setting the depth L1 of the mounting groove 122 in the axial direction of the core body to be greater than or equal to the height H1 of the edge protrusion in the axial direction of the core body, assembly interference between the insulating frame 14 and the segmented core 12 can be effectively avoided.

[0085] In some embodiments, as Figure 5 As shown, the maximum magnetic density T1 of the tooth portion 126 of the segmented iron core 12 covered by the insulating protrusion 142, the maximum magnetic density T2 of the tooth portion 126 of the segmented iron core 12 not covered by the insulating protrusion 142, the width D1 of the mounting groove 122 on a cross section of the core body, and the width D2 of the tooth portion 126 of the segmented iron core 12 not covered by the insulating protrusion 142 satisfy D1≤D2(T1-T2) / T1.

[0086] In this embodiment, since the present application provides mounting grooves 122 at the edges of both end surfaces of the segmented iron core 12, the width of the tooth portion 126 and / or the yoke portion 124 of the segmented iron core 12 in the end area will be narrowed. Since the yoke portion 124 and the tooth portion 126 of the segmented iron core 12 are both the magnetic circuits of the motor, the narrowing of the width of the above-mentioned tooth portion 126 and the yoke portion 124 in the end area will cause the magnetic density of the segmented iron core 12 to increase and the iron loss to increase, especially the impact on the tooth portion 126 is greater. Therefore, in order to reduce the above-mentioned impact on motor loss, the maximum width D1 of the mounting groove 122 on a cross section of the core body is set to satisfy the following relationship: D2(T1-T2) / T1, wherein D2 is the width of the effective area of ​​the tooth portion 126 of the segmented core 12, that is, the width of the tooth portion 126 of the segmented core 12 not covered by the insulating protrusion 142, T1 is the maximum magnetic density of the tooth portion 126 of the segmented core 12 covered by the insulating protrusion 142, and T2 is the maximum magnetic density of the tooth portion 126 of the segmented core 12 not covered by the insulating protrusion 142. The magnetic density is the magnetic flux density, which can effectively prevent the magnetic flux density of the tooth portion 126 from exceeding the working saturation point, causing a sharp increase in iron loss.

[0087] Among them, the maximum magnetic density of the tooth portion 126 of the segmented iron core 12 covered by the insulating protrusion 142 and the maximum magnetic density of the tooth portion 126 of the segmented iron core 12 not covered by the insulating protrusion 142, that is, the maximum magnetic flux density are both set according to the motor speed and motor load, and can also be set according to the material of the segmented iron core 12 and / or the required motor efficiency. Specifically, when the material of the punching sheets constituting the segmented iron core 12 is silicon steel plate, the maximum magnetic flux density of the tooth portion 126 of the segmented iron core 12 covered by the insulating protrusion 142 can be set to 2.0T (where T is the unit of magnetic flux density, Tesla). Since in related technologies, the magnetic flux density of the tooth portion of the segmented iron core is generally 1.6T to 1.8T, the maximum magnetic flux density of the tooth portion 126 of the segmented iron core 12 not covered by the insulating protrusion 142 can be set to 1.6T, and the relationship between D1 and D2 can be: D1≤D2(2.0T-1.6T) / 2.0T.

[0088] In some embodiments, a width D1 of the mounting groove 122 in a cross section of the core body and a width D2 of the teeth 126 of the segmented core 12 not covered by the insulating protrusion 142 satisfy D1≤0.2D2.

[0089] In this embodiment, by setting the width D1 of the mounting slot 122 in a cross-section of the core body to be less than or equal to 0.2 times the width D2 of the teeth 126 of the segmented core 12 not covered by the insulating protrusion 142, the segmented core 12 can be effectively prevented from excessively narrowing the width of the teeth 126 and / or yoke 124 at the end regions of the segmented core 12, which could lead to an excessive increase in the magnetic flux density of the segmented core 12, particularly an excessive increase in the magnetic flux density of the teeth 126 of the segmented core 12, which could lead to a sharp increase in iron loss. In particular, when the laminations constituting the segmented core 12 are made of silicon steel sheets, the segmented core 12 is applicable to various motor speeds and loads, and can meet various required motor efficiencies. For example, the maximum magnetic flux density of the teeth 126 of the segmented iron core 12 covered by the insulating protrusions 142 can be 1.8T or 1.8T or 1.3T, etc., and the corresponding maximum magnetic flux density of the teeth 126 of the segmented iron core 12 not covered by the insulating protrusions 142 can be 1.5T or 1.7T or 1.1T, etc., which are not listed here one by one.

[0090] In some embodiments, as Figure 5 As shown, the width D1 of the mounting groove 122 on a cross section of the core body and the width D2 of the teeth 126 of the segmented core 12 not covered by the insulating protrusion 142 satisfy 0.05D2≤D1.

[0091] In this embodiment, by setting the width D1 of the mounting groove 122 on a cross-section of the core body to be greater than or equal to 0.05 times the width D2 of the teeth 126 of the segmented core 12 not covered by the insulating protrusion 142, this not only facilitates the mounting groove 122 to have a sufficient width to facilitate the insertion of the insulating protrusion 142, but also facilitates the insertion of a sufficiently thick insulating protrusion 142 into the mounting groove 122, thereby improving the insulation performance of the core assembly 10. In particular, when the insulating protrusion 142 is integrally injection-molded with the insulating frame 14, this avoids requiring the insulating protrusion 142 to be excessively thin in order to be inserted into the mounting groove 122, thereby facilitating the processing of the insulating protrusion 142. The value of 0.05 was determined after multiple experiments, taking into account the above factors.

[0092] In some embodiments, the width D1 of the mounting slot 122 in a cross section of the segmented core 12 is the same or different across the entire width.

[0093] In some embodiments, the core assembly 10 further includes an insulating member disposed in a winding slot 16 formed by two adjacent segmented cores 12 .

[0094] In this embodiment, an insulating member is provided in the winding slot 16 formed by two adjacent segmented cores 12 to ensure the insulation of the core assembly 10 .

[0095] In some embodiments, the insulating member is formed by the portion of the insulating frame 14 that extends into the winding groove 16. That is, in addition to the insulating protrusion 142, the insulating frame 14 also has an insulating portion that extends into the winding groove 16 for insulation, and the insulating portion covers the sidewalls of the winding groove 16.

[0096] In some embodiments, the insulating member is slot insulation paper 18. Furthermore, the slot insulation paper 18 includes two extensions 182, which are distributed at both ends of the slot insulation paper 18 along the axial direction of the core body. Each extension 182 extends along the axial direction of the core body, and the extension 182 is located in the gap between two adjacent insulation frames 14.

[0097] In this embodiment, slot insulation paper 18 is provided within the winding slot 16 for insulation. Compared to the insulation method where an insulating frame is installed at both ends of the segmented core and extends into the winding slot, since the insulating frame is typically manufactured using an injection molding process and then installed in conjunction with the winding slot, the portion of the insulating frame extending into the winding slot is relatively thick, occupying a large area of ​​the winding slot. In contrast, by providing slot insulation paper 18 within the winding slot 16, the present application can reduce the space occupied by the winding slot 16 while maintaining the insulation effect, thereby ensuring the utilization rate of the winding slot 16.

[0098] In addition, since the insulating skeleton 14 corresponding to the segmented core 12 is also arranged in segments, there will be a gap between the two adjacent insulating skeletons 14 on the two adjacent segmented cores 12. While the thickness of the end of the insulating skeleton 14 is reduced, the height of the slot insulating paper 18 matched therewith in the axial direction of the core body is also reduced. Therefore, by arranging the slot insulating paper 18 in the winding slot 16 and setting the protruding portions 182 of the slot insulating paper 18 at both ends along the axial direction of the core body to be located in the gap between the two adjacent insulating skeletons 14, the gap between the two adjacent insulating skeletons 14 is blocked, and the insufficient creepage distance between the gap between the adjacent insulating skeletons 14 and the segmented core 12 caused by the reduced thickness of the end of the insulating skeleton 14 can be compensated, and the creepage distance can be increased to ensure that the creepage distance between the core assembly 10 and the winding at the gap is sufficient, thereby ensuring the insulation reliability of the core assembly 10.

[0099] In some embodiments, as Figure 6 and Figure 7 As shown, the length H2 of the extension portion 182 extending in the axial direction of the core body and the height H1 of the insulating protrusion 142 in the axial direction of the core body satisfy H2 ≥ H1.

[0100] In this embodiment, by setting the axial extension length H2 of the protrusion 182 along the core body to be greater than or equal to the axial height H1 of the insulating protrusion 142 on the core body, it is helpful to compensate for sufficient creepage distance so that the creepage distance meets the national standard or the customer's insulation safety requirements for the product.

[0101] In some embodiments, the insulating frame 14 is made of liquid crystal polymer containing glass fiber or polybutylene terephthalate containing glass fiber.

[0102] In this embodiment, the insulating frame 14 is made of liquid crystal polymer (LCP) containing glass fiber or polybutylene terephthalate (PBT) containing glass fiber, so that the insulating effect is good.

[0103] In some embodiments, the slot insulation paper 18 is made of polyethylene terephthalate plastic, polyethylene naphthalate, or polyphenylene sulfide.

[0104] In this embodiment, by setting the material of the slot insulation paper 18 to polyethylene terephthalate (PET), polyethylene naphthalate (PEN), or polyphenylene sulfide (PPS), the insulation effect is good and it is not easy to be damaged.

[0105] A second embodiment of the present invention provides a motor, comprising: an iron core assembly 10 as described in any one of the above embodiments.

[0106] The motor provided by the present invention, because it includes the core assembly 10 of any of the above-mentioned embodiments, thus has the beneficial effects of any of the above-mentioned embodiments, which will not be described in detail here. The motor includes a stator and a rotor. Optionally, the stator includes windings and the core assembly 10 of any of the above-mentioned embodiments. In this case, the winding slots 16 are stator slots. Of course, the rotor may also include the core assembly 10 of any of the above-mentioned embodiments, and the winding slots 16 are rotor slots. The motor is preferably a rotating motor.

[0107] A third aspect of the present invention provides a compressor, comprising: a motor as described in any one of the above embodiments.

[0108] The compressor provided by the present invention has the motor of any one of the above embodiments, and thus has the beneficial effects of any of the above embodiments, which will not be described in detail here.

[0109] A fourth aspect of the present invention provides a vehicle, comprising: a compressor as described in any one of the above embodiments.

[0110] The vehicle provided by the present invention has the compressor of any one of the above embodiments, and thus has the beneficial effects of any of the above embodiments, which will not be described in detail here.

[0111] Of course, the compressor is not limited to being installed in a vehicle, but can also be installed in other equipment including a refrigeration system, such as air-conditioning equipment.

[0112] In the present invention, the term "plurality" refers to two or more, unless otherwise specified. Terms such as "installed," "connected," "connected," and "fixed" should be interpreted broadly. For example, "connected" can mean fixed, removable, or integral; and "connected" can mean directly or indirectly through an intermediary. Those skilled in the art will understand the specific meanings of these terms in the present invention based on specific circumstances.

[0113] Throughout this specification, terms such as "one embodiment," "some embodiments," and "specific embodiments" mean that the specific features, structures, materials, or characteristics described in conjunction with that embodiment or example are included in at least one embodiment or example of the present invention. In this specification, schematic representations of these terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0114] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations of the present invention are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of protection of the present invention.

Claims

1. A core assembly, characterized in that: include: An iron core body, the iron core body comprising a plurality of segmented iron cores, each of the segmented iron cores having an installation groove at an edge of at least one end surface; Multiple insulating frames, each of the segmented iron cores is disposed between two of the insulating frames, and the insulating frames are distributed at both ends of a segmented iron core. At least one of the insulating frames has an insulating protrusion on one end surface facing the segmented iron core for covering both sides of the segmented iron core, and the insulating protrusion cooperates with the mounting groove; Wherein, the insulating protrusion and the insulating frame are integrally formed; Wherein, the insulating protrusions are coated on both sides of the entire segmented iron core; The maximum magnetic density T1 of the tooth portion of the segmented iron core covered by the insulating protrusion, the maximum magnetic density T2 of the tooth portion of the segmented iron core not covered by the insulating protrusion, the width D1 of the mounting groove on a cross section of the core body, and the width D2 of the tooth portion of the segmented iron core not covered by the insulating protrusion satisfy D1≤D2(T1-T2) / T1.

2. The core assembly according to claim 1, wherein: The segmented iron core includes a yoke portion, a tooth portion, and a pole shoe portion, and the insulating protrusion at least covers both sides of the tooth portion and the pole shoe portion.

3. The core assembly according to claim 2, wherein: The insulating protrusion further covers a side of the yoke portion facing the tooth portion.

4. The core assembly according to any one of claims 1 to 3, characterized in that: Two adjacent mounting grooves on two adjacent segmented iron cores are in contact and connected.

5. The core assembly according to any one of claims 1 to 3, characterized in that: A depth L1 of the mounting groove in the axial direction of the core body and a height H1 of the insulating protrusion in the axial direction of the core body satisfy H1≤L1.

6. The core assembly according to any one of claims 1 to 3, characterized in that: A width D1 of the mounting groove in a cross section of the core body and a width D2 of the teeth of the segmented core not covered by the insulating protrusion satisfy D1≤0.2D2.

7. The core assembly according to any one of claims 1 to 3, characterized in that: A width D1 of the mounting groove in a cross section of the core body and a width D2 of the teeth of the segmented core not covered by the insulating protrusion satisfy 0.05D2≤D1.

8. The core assembly according to any one of claims 1 to 3, characterized in that: The width D1 of the mounting groove on a cross section of the segmented core is the same or different at all locations.

9. The core assembly according to any one of claims 1 to 3, characterized in that: The core assembly further comprises: The insulating member is arranged in a winding slot formed by two adjacent segmented iron cores.

10. The core assembly according to claim 9, wherein: The insulating member is slot insulation paper; The slot insulation paper includes two protruding parts, which are distributed at both ends of the slot insulation paper along the axial direction of the core body. Each protruding part extends along the axial direction of the core body, and the protruding part is located in the gap between two adjacent insulation frames.

11. The core assembly according to claim 10, wherein: A length H2 of the protruding portion extending in the axial direction of the core body and a height H1 of the insulating protrusion in the axial direction of the core body satisfy H2≥H1.

12. The core assembly according to claim 10, wherein: The insulating frame is made of liquid crystal polymer containing glass fiber or polybutylene terephthalate containing glass fiber; and / or The slot insulation paper is made of polyethylene terephthalate plastic, polyethylene naphthalate, or polyphenylene sulfide.

13. A motor, characterized in that: include: The core assembly according to any one of claims 1 to 12.

14. A compressor, characterized in that: include: The motor as claimed in claim 13.

15. A vehicle, characterized in that: include: The compressor of claim 14.

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