An insulation paper structure for covering a conductor in a slot of an electric machine

Abstract

The application discloses an insulating paper structure for coating conductors in motor slots, which comprises at least two conductor accommodating cavities which are adjacent to each other and are formed by bending the insulating paper, and the at least two conductor accommodating cavities constitute a group of slot liners; the first end and the end of the insulating paper are bent and are overlapped with each other to form a lower end wall of the lower conductor accommodating cavity, and the upper and lower two bottom walls and the top wall between the two adjacent conductor accommodating cavities are formed by bending the inner side wall of the insulating paper to the left and right and being fixed at the folding lines, the upper left and right two upper folding surfaces constitute the bottom wall of the upper conductor accommodating cavity, and the lower left and right two lower folding surfaces constitute the top wall of the lower conductor accommodating cavity; one piece of insulating paper is used for each slot conductor, and the preparation of the stator slot liner in the slot can be completed by folding, and the number of the conductors in the slot is not limited, and the insulating paper in the slot can be folded to be single.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of new energy automobile drive motor, and particularly relates to an insulating paper structure for coating a conductor in a motor slot. BACKGROUND

[0002] The adoption of a flat wire winding scheme by a new energy automobile drive motor has become an important way to improve the slot fill rate of the motor. The flat wire winding scheme adopts rectangular copper wire. Compared with the round copper wire winding scheme, the thin round copper wire has a significant cross-sectional area change. The rectangular conductor winding scheme has a smaller gap between the flat wires than the thin round conductor winding scheme. More winding copper wires can be installed in the same stator slot volume, and therefore the slot fill rate of the flat wire motor can be as high as 70%. With a high slot fill rate, the flat wire motor has less copper wire filling for the same motor power, and the size of the stator core and the end part can be reduced, so that the size of the motor is also smaller, and the material is saved while the motor power density is further improved. The stator of the flat wire motor has a smaller slot size compared with the round wire motor, which can effectively reduce the cogging torque and thus reduce the electromagnetic noise.

[0003] The flat wire winding motor can be divided into concentrated winding flat wire motor, wave winding flat wire motor and Hairpin (hairpin) flat wire motor according to the product type. The Hairpin flat wire motor technology is the mainstream technology widely used.

[0004] The flat wire winding motor has the following deficiencies. The skin effect has a greater impact on the flat wire winding motor. When there is alternating current or alternating magnetic field in the conductor, the current distribution in the conductor is uneven. The closer to the surface of the conductor, the greater the current density. The effective current-carrying copper wire area is reduced, the equivalent resistance of the winding is increased, and the high-frequency alternating current loss is increased. The length-width ratio, placement direction and winding phase of the conductor all have an impact on the skin effect. The skin effect of the same slot winding is more serious than that of the different slot winding. With the same slot depth and slot width, increasing the number of conductor layers is beneficial to reducing the skin effect. In order to further reduce the alternating current loss caused by the skin effect, the flat wire winding motor adopts the method of increasing the number of conductor layers for optimization, from the 4-layer, 6-layer and 8-layer schemes that have been applied to the 12-layer and 16-layer schemes that are being researched.

[0005] In addition to the insulating paint film insulation between the flat wire winding copper wires, the stator slot liner is also used to separate the conductors from each other to eliminate the direct contact between the turns or the conductors and the stator core, improve the insulation performance and enhance the short circuit protection. The insulating slot paper is usually used as the slot liner. Common insulating paper structures include O-type, C-type, B-type and S-type. The complex insulating paper structure increases the process step difficulty during the wire embedding, and the precision requirement of the numerical control installation equipment is also higher. Therefore, the pursuit of a simpler and more optimal winding insulation structure has become an important research direction for the application of the flat wire winding.

[0006] The existing B-type and S-type insulation paper structures are only applicable to motors with even layers of conductors, and a plurality of insulation paper structures need to be combined for use for odd layers of conductors; the S-type insulation paper structure has a gap at a corner; the depth dimension of the middle layer of the B-type insulation paper structure is difficult to control, and if the depth dimension of the middle layer is insufficiently reserved, conductor turn-to-turn insulation is not conducive.

[0007] The O-type insulation paper structure does not limit the number of layers of conductors of a motor, but is not conducive to conductor turn-to-turn insulation. If the O-type insulation paper structure is used for each layer of conductors, process simplification and consistency of insulation paper arrangement in each slot are not conducive. SUMMARY

[0008] To solve the above problems, the application provides an insulation paper structure for covering conductors in a motor slot, which does not require the motor to have even layers of conductors, has the advantages of the B-type insulation paper structure, can eliminate the gap of the S-type insulation paper structure at the corner, has a similar amount of insulation paper as the B-type insulation paper structure, can avoid the difficulty in controlling the depth dimension of the middle layer of the B-type insulation paper structure, simplifies the process step difficulty during embedding, and can be cut and prepared in advance according to the amount of insulation paper, so that one piece of insulation paper is used for each slot conductor through folding to complete the preparation of the stator slot liner in the slot, without limiting the number of layers of conductors in the slot, and the insulation paper in the slot can be folded with a single sheet.

[0009] The insulation paper structure for covering conductors in a motor slot of the application is integrally bent by insulation paper to form at least two conductor accommodating cavities adjacent to each other, and the at least two conductor accommodating cavities adjacent to each other constitute a group of slot liners. The application can integrally bend an odd number of conductor accommodating cavities to form a group of slot liners in a single stator slot, or integrally bend an even number of conductor accommodating cavities to form a group of slot liners in a single stator slot, has the advantages of the B-type insulation paper structure, has a similar amount of insulation paper as the B-type insulation paper structure, can avoid the difficulty in controlling the depth dimension of the middle layer of the B-type insulation paper structure, simplifies the process step difficulty during embedding, and can be cut and prepared in advance according to the amount of insulation paper, so that one piece of insulation paper is used for each slot conductor through folding to complete the preparation of the stator slot liner in the slot, without limiting the number of layers of conductors in the slot, and the insulation paper in the slot can be folded with a single sheet.

[0010] The first end and the end of the insulating paper are bent and overlapped to form a cavity lower end wall of the lower end conductor accommodating cavity, and the upper and lower two bottom walls and the top wall between every two adjacent conductor accommodating cavities are formed by inwardly bending the left and right inner side walls of the insulating paper and fixed at the folding lines, and the upper left and right two folding surfaces form the upper conductor accommodating cavity bottom wall, and the lower left and right two folding surfaces form the lower conductor accommodating cavity top wall. The same insulating paper is used to fold to form the conductor accommodating cavity, and the preparation of the stator slot liner in the slot can be completed, and the number of conductors in the slot is not limited, and the insulating paper in the slot can be folded by a single sheet.

[0011] The fixing mode at the folding line where the insulating paper is inwardly bent left and right is adhesive fixing, and the fixing between the two corresponding folding lines is to eliminate the gap between the two folding lines and ensure the insulation between the upper conductor accommodating cavity and the adjacent lower conductor accommodating cavity.

[0012] The fixing mode at the folding line where the insulating paper is inwardly bent left and right is the insertion fixing of mortise and tenon structure, and the fixing between the two corresponding folding lines is to eliminate the gap between the two folding lines and ensure the insulation between the upper conductor accommodating cavity and the adjacent lower conductor accommodating cavity.

[0013] The upper folding surface or the lower folding surface of the insulating paper in the middle of the left and right corresponding folding lines is horizontally cut to form a horizontal insertion tongue, and the corresponding position of the other side of the folding line is matched and cut to form a horizontal insertion slot, the horizontal insertion tongue of the one side of the folding line is horizontally inserted into the horizontal insertion slot of the other side of the folding line, and the upper and lower surfaces of the horizontal insertion tongue are correspondingly clamped and fixed between the upper and lower two folding surfaces of the folding line where the horizontal insertion slot is located, the insertion connection of the mortise and tenon structure is to make the two horizontally corresponding folding lines tightly contact, eliminate the gap between the two corresponding folding lines, and ensure the insulation between the upper conductor accommodating cavity and the adjacent lower conductor accommodating cavity.

[0014] The upper folding surface and the lower folding surface connected by the one side of the folding surface forming the bottom wall and the top wall of the adjacent conductor accommodating cavity are adhesively fixed to ensure that the same side of the cut-out hollow folding surface and the uncut folding surface are tightly adhesively fixed, and the insulation between the upper conductor accommodating cavity and the adjacent lower conductor accommodating cavity is ensured; the upper folding surface and the lower folding surface connected by the other side of the corresponding folding surface forming the bottom wall and the top wall of the adjacent conductor accommodating cavity are adhesively fixed.

[0015] The left and right side walls of the front or rear part of the upper conductor accommodating cavity are respectively cut at the fold lines between the left and right two pairs of folds constituting the bottom wall with a vertical insertion strip slot; the left and right two pairs of folds constituting the top wall of the lower conductor accommodating cavity are respectively cut at the upper end fold lines of the left and right side walls with a vertical insertion tab corresponding to the position of the vertical insertion strip slot of the upper conductor accommodating cavity, and the left and right two vertical insertion tabs of the lower conductor accommodating cavity are respectively vertically inserted into the left and right two vertical insertion strip slots of the upper conductor accommodating cavity, and the outer surface of each vertical insertion tab is in contact with the inner surface of the corresponding side wall, and the left and right two vertical insertion tabs are inserted into the left and right two vertical insertion strip slots, and the mortise and tenon structure of the insertion tab and the strip slot makes the left and right two pairs of folds constituting the bottom wall of the upper conductor accommodating cavity and the left and right two pairs of folds constituting the top wall of the lower conductor accommodating cavity closely adhere to each other, ensuring that the same side cut-out hollowed folds and the uncut folds are closely adhered and fixed, and ensuring the insulation between the upper conductor accommodating cavity and the adjacent lower conductor accommodating cavity.

[0016] The left and right two pairs of folds constituting the bottom wall of the front or rear part of the upper conductor accommodating cavity are respectively cut at the lower end fold lines of the left and right side walls with a vertical insertion tab; the left and right side walls of the lower conductor accommodating cavity are respectively cut at the upper fold lines between the left and right two pairs of folds constituting the top wall with a vertical insertion strip slot corresponding to the position of the vertical insertion tab of the upper conductor accommodating cavity, and the left and right two vertical insertion tabs of the upper conductor accommodating cavity are respectively vertically inserted into the left and right two vertical insertion strip slots of the lower conductor accommodating cavity, and the outer surface of each vertical insertion tab is in contact with the inner surface of the corresponding side wall, and the left and right two vertical insertion tabs are inserted into the left and right two vertical insertion strip slots, and the mortise and tenon structure of the insertion tab and the strip slot makes the left and right two pairs of folds constituting the top wall of the lower conductor accommodating cavity and the left and right two pairs of folds constituting the bottom wall of the upper conductor accommodating cavity closely adhere to each other, ensuring that the same side cut-out hollowed folds and the uncut folds are closely adhered and fixed, and ensuring the insulation between the upper conductor accommodating cavity and the adjacent lower conductor accommodating cavity.

[0017] The width of the horizontal insertion tab is 1 / 2-1 of the width of the upper or lower pair of folds on which the horizontal insertion tab is cut.

[0018] The height of the vertical insertion tab is 1 / 3-1 of the width of the upper or lower pair of folds on which the vertical insertion tab is cut.

[0019] The application discloses an insulating paper structure for covering conductors in motor slots, which is composed of a plurality of groups of slot liners connected in horizontal direction, the setting structure of horizontal insertion tongues and horizontal insertion slits of every two adjacent slot liners is symmetrical or antisymmetrical, the setting structure of vertical insertion tongues and vertical insertion slits of every two adjacent slot liners is symmetrical or antisymmetrical, the setting of horizontal two or more groups of slot liners is adapted to stator slots with different slot depths, and the structure of horizontal groups of slot liners ensures that there is no gap between corresponding folding lines of the insulating paper structure which is integrally bent and formed, and the insulation between the upper conductor accommodating cavity and the adjacent lower conductor accommodating cavity is ensured.

[0020] Advantages

[0021] The application does not require the motor to have an even number of conductors, has the advantages of the B-type insulating paper structure, and can eliminate the gap at the corner of the S-type insulating paper structure; the amount of insulating paper is equivalent to that of the B-type insulating paper structure, and the difficulty in controlling the depth size of the middle layer of the B-type insulating paper structure is avoided, thereby simplifying the process step difficulty during wire embedding; the insulating paper can be cut and prepared in advance according to the amount of insulating paper, and one piece of insulating paper is used to complete the preparation of the stator slot liner in the slot by folding, so that the number of layers of the conductor in the slot is not limited, and the insulating paper in the slot can be folded by a single piece. BRIEF DESCRIPTION OF DRAWINGS

[0022] Figure 1 is a front view of an embodiment of the application.

[0023] Figure 2 is a front view of an embodiment of the application.

[0024] Figure 3 is a rear view of an embodiment of the application.

[0025] Figure 4 is an expanded structure diagram of an embodiment of the application.

[0026] Figure 5 is a structure diagram of an embodiment of the application installed in a stator slot.

[0027] Figure 6 is Figure 5 a single stator slot.

[0028] Figure 7 is an expanded structure diagram of another embodiment of the application. Figure 1 .

[0029] Figure 8 is an expanded structure diagram of another embodiment of the application. Figure 2 .

[0030] In the figure:

[0031] 1, Insulating paper; 11, Slot lining; 12, Head end; 13, Tail end; 14, Fold line; 15, Upper folded surface; 16, Lower folded surface; 17, Lower fold line; 18, Upper fold line;

[0032] 2, Conductor accommodating cavity;

[0033] 3, Horizontal insertion tongue;

[0034] 4, Horizontal insertion slot;

[0035] 5, Vertical insertion slot;

[0036] 6, Vertical insertion tongue;

[0037] 7, Stator core;

[0038] 71, Stator slot. DETAILED DESCRIPTION

[0039] In order to make the technical problems solved by the present application, the technical solutions adopted and the technical effects achieved more clear, the technical solutions of the present application will be further described below in conjunction with the accompanying drawings and through specific embodiments. It can be understood that the specific embodiments described herein are only used to explain the present application, but not to limit the present application. In addition, it should be noted that, for the convenience of description, only the parts related to the present application are shown in the drawings, but not all.

[0040] In the description of the present application, it should be noted that the orientation or positional relationship indicated by the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer" and the like is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present application and simplifying the description, and therefore cannot be understood as indicating or implying that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application. In addition, the terms "first", "second" are only for the purpose of description, and cannot be understood as indicating or implying relative importance. Among them, the terms "first position" and "second position" are two different positions.

[0041] In the description of the present application, it should be noted that, unless otherwise explicitly specified and limited, the terms "mounting", "connecting", "connection" should be understood in a broad sense, for example, it can be fixed connection, or it can be detachable connection; it can be mechanical connection, or it can be electrical connection; it can be directly connected, or it can be indirectly connected through an intermediate medium; it can be the communication inside two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0042] Example 1

[0043] The insulating paper structure for covering the conductors in the motor slot is formed by integrally bending the insulating paper 1 to form two conductor accommodating cavities 2 which are adjacent to each other in the upper and lower directions, and the two conductor accommodating cavities constitute a group of slot liners 11.

[0044] The first end 12 and the end 13 of the insulating paper 1 are bent to form the lower end walls of the lower conductor accommodating cavities, and the adjacent upper and lower bottom walls and the top wall between the adjacent conductor accommodating cavities 2 are formed by bending the inner side walls of the insulating paper 1 to the left and right and inwardly at the folding lines 14, and are fixed by being in contact with each other at the folding lines 14, the upper left and right upper folding surfaces 15 constitute the bottom walls of the upper conductor accommodating cavities, and the lower left and right lower folding surfaces 16 constitute the top walls of the lower conductor accommodating cavities.

[0045] The fixing mode at the folding lines 14 where the insulating paper 1 is bent inwardly to the left and right is adhesive fixing.

[0046] The upper folding surface 15 and the lower folding surface 16 connected by the folding line 14 on one side of the folding surface constituting the bottom wall and the top wall of the adjacent conductor accommodating cavities 2 are adhesively fixed, and the upper folding surface 15 and the lower folding surface 16 connected by the folding line 14 on the other side of the folding surface constituting the bottom wall and the top wall of the adjacent conductor accommodating cavities 2 are adhesively fixed.

[0047] After the insulating paper of the motor is integrally bent and preformed, it is placed in the stator slot of the motor, then the conductors of the motor are placed one by one into the conductor accommodating cavities formed by the insulating paper, after the shaping of the end (outlet end) of the motor conductor, the motor stator assembly is subjected to the dipping or immersion paint process, at this time the gap between the integrally bent and preformed insulating paper and the motor conductor is filled and covered by the insulating paint.

[0048] Embodiment 2

[0049] As shown in Figures 1-6 The insulating paper structure for covering the conductors in the motor slot is suitable for a flat wire motor, and the stator assembly of the flat wire motor includes an annular stator core 7, the inner side of the stator core 7 is provided with a plurality of long strip-shaped stator slots 71, the stator slots 71 are arranged in the circumferential direction of the stator core 7 and are spaced apart, and each stator slot 71 is arranged in the radial direction of the stator core 7; five enameled flat copper wires are arranged in the stator slot 71 along the length direction of the stator slot 71, and each flat copper wire constitutes a conductor; the insulating paper structure is arranged in the stator slot 71 and is used to realize the insulation between each conductor and the stator core 7 and between adjacent conductors; the number of enameled flat copper wires in the stator slot 71 can be set according to the needs of the motor.

[0050] As shown in Figures 1-6 The insulating paper structure for covering the conductors in the motor slot is different from that of embodiment 1 in that two conductor accommodating cavities 2 which are adjacent to each other in the upper and lower directions are formed by integrally bending the insulating paper 1, and the two conductor accommodating cavities constitute a group of slot liners 11.

[0051] The first end 12 and the last end 13 of the insulating paper 1 are folded and overlapped to form the lower end wall of the conductor accommodating cavity. The upper and lower two bottom walls and the top wall between every two adjacent conductor accommodating cavities 2 are formed by inwardly folding the left and right inner walls of the insulating paper 1 and fixed at the folding line 14. The left and right upper folding surfaces 15 constitute the upper bottom wall of the conductor accommodating cavity. The left and right lower folding surfaces 16 constitute the top wall of the conductor accommodating cavity.

[0052] The fixing method at the folding line 14 where the left and right inner walls of the insulating paper 1 are inwardly folded is adhesive fixing.

[0053] The fixing method at the middle part of the folding line 14 where the left and right inner walls of the insulating paper 1 are inwardly folded is mortise and tenon structure insertion fixing.

[0054] The lower folding surface 16 of the insulating paper 1 at the middle part of the folding line 14 on one side is cut horizontally to form a horizontal insertion tongue 3. The folding line 14 on the other side is cut horizontally to form a horizontal insertion slot 4. The horizontal insertion tongue 3 on one side is inserted into the horizontal insertion slot 4 on the other side. The upper and lower surfaces of the horizontal insertion tongue 3 are fixed between the upper and lower folding surfaces of the folding line 14 where the horizontal insertion slot 4 is located.

[0055] The left and right side walls at the rear part of the upper conductor accommodating cavity 2 and the lower folding line 17 of the left and right folding surfaces constituting the bottom wall are respectively cut vertically to form a vertical insertion slot 5. The left and right folding surfaces constituting the top wall of the lower conductor accommodating cavity 2 and the upper folding line 18 of the left and right side walls are respectively cut vertically to form a vertical insertion tongue 6. The left and right vertical insertion tongues 6 of the lower conductor accommodating cavity 2 are vertically inserted into the left and right vertical insertion slots 5 of the upper conductor accommodating cavity 2. The outer surface of each vertical insertion tongue 6 is in contact with the inner surface of the corresponding side wall.

[0056] The width of the horizontal insertion tongue 3 is 1.5 / 2 of the width of the lower folding surface 16 where the horizontal insertion tongue 3 is cut.

[0057] The height of the vertical insertion tongue 6 is 2 / 3 of the width of the lower folding surface 16 where the vertical insertion tongue 6 is cut.

[0058] Working principle

[0059] Referring to Figures 1-4 The insulating paper structure for covering the conductors in the motor slot is formed by inwardly folding and outwardly folding a flat insulating paper 1 to form a group of slot liners 11 with five conductor accommodating cavities 2 adjacent to each other.

[0060] Folding, bending and cutting of the insulation paper:

[0061] Referring to Figure 4 As shown in the figure, the insulation paper is provided with 29 columns in total, with O column in the middle;

[0062] From O column to the left, there are 14 columns in total, which are A column, B column, C column, D column, E column, F column, G column, H column, I column, J column, K column, L column, M column and N column in sequence. There are folding lines 14 outwardly folding by 180° between B column and C column, between E column and F column, between H column and I column, and between K column and L column. There are folding lines between O column and A column, between A column and B column, between C column and D column, between D column and E column, between F column and G column, between G column and H column, between I column and J column, between J column and K column, between L column and M column, and between M column and N column, which are inwardly bent by 90°. The folding lines between A column and B column, between D column and E column, between G column and H column, and between J column and K column form lower folding lines 17 of the lower end of the left side wall of the upper four conductor accommodating cavities. The folding lines between C column and D column, between F column and G column, between I column and J column, and between L column and M column form upper folding lines 18 of the upper end of the left side wall of the lower four conductor accommodating cavities. After the folding line between M column and N column is bent, N column (i.e. the first end 12 of the insulation paper) forms the lower left end wall of the lower conductor accommodating cavity 2. The middle part of the folding lines 14 between B column and C column, between E column and F column, between H column and I column, and between K column and L column are respectively cut with horizontal insertion slits 4. The lower folding lines 17 between A column and B column, between D column and E column, between G column and H column, and between J column and K column are respectively cut with vertical insertion slits 5. The upper folding lines 18 between C column and D column, between F column and G column, between I column and J column, and between L column and M column are respectively cut with vertical insertion tabs 6 corresponding to the positions of the vertical insertion slits 5;

[0063] From O column to right a total of 14 columns, in turn, are a column, b column, c column, d column, e column, f column, g column, h column, i column, j column, k column, l column, m column, n column; b column and c column, e column and f column, h column and i column, k column and l column are outwardly folded 180° fold line 14, O column and a column, a column and b column, c column and d column, d column and e column, f column and g column, g column and h column, i column and j column, j column and k column, l column and m column, m column and n column are inwardly bent 90° fold line, the fold line between a column and b column, d column and e column, g column and h column, j column and k column constitutes the lower fold line 17 of the lower end of the right side wall of the upper four conductor accommodating cavities, the fold line between c column and d column, f column and g column, i column and j column, l column and m column constitutes the upper fold line 18 of the upper end of the right side wall of the lower four conductor accommodating cavities, the fold line between m column and n column is bent, so that n column (that is, the end 13 of the insulating paper) constitutes the right lower end wall of the lower end conductor accommodating cavity 2, the middle part of the fold line 14 between b column and c column, e column and f column, h column and i column, k column and l column is cut respectively according to the position of the left horizontal insertion slot 4, the lower part of the lower fold line 17 between a column and b column, d column and e column, g column and h column, j column and k column is cut respectively according to the position of the vertical insertion slot 5, the upper fold line 18 between c column and d column, f column and g column, i column and j column, l column and m column is cut respectively according to the position of the vertical insertion slot 5;

[0064] The insulating paper is assembled to form a group of groove liners:

[0065] The composition of the side walls of the five conductor accommodating cavities

[0066] The fold line between O column and A column and the fold line between O column and a column are bent inwardly by 90°, so that A column and a column constitute the left and right side walls of the upper end conductor accommodating cavity; by analogy, the fold line between C column and D column, the fold line between F column and G column, the fold line between I column and J column, the fold line between L column and M column, the fold line between c column and d column, the fold line between f column and g column, the fold line between i column and j column, and the fold line between l column and m column are bent inwardly by 90°, respectively, so that D column and d column constitute the left and right side walls of the upper second conductor accommodating cavity, G column and g column constitute the left and right side walls of the upper third conductor accommodating cavity, J column and j column constitute the left and right side walls of the upper fourth conductor accommodating cavity, and M column and m column constitute the left and right side walls of the fifth conductor accommodating cavity from top to bottom;

[0067] The composition of the top wall and the bottom wall of the five conductor accommodating cavities

[0068] The O column of the insulating paper constitutes the top wall of the upper conductor accommodating cavity. The folding line 14 between the B column and the C column after folding and the folding line 14 between the b column and the c column after folding are in contact, constituting the upper bottom wall and the lower top wall between the adjacent first and second conductor accommodating cavities. The horizontal insertion tab 3 on the folding line 14 between the b column and the c column is horizontally inserted into the horizontal insertion slot 4 on the folding line 14 between the B column and the C column, avoiding the gap between the folding lines to ensure the insulation between the two conductor accommodating cavities above and below. Similarly, the folding line 14 between the E column and the F column and the folding line 14 between the e column and the f column are in contact, constituting the upper bottom wall and the lower top wall between the adjacent second and third conductor accommodating cavities. The folding line 14 between the H column and the I column and the folding line 14 between the h column and the i column are in contact, constituting the upper bottom wall and the lower top wall between the adjacent third and fourth conductor accommodating cavities. The folding line 14 between the K column and the L column and the folding line 14 between the k column and the l column are in contact, constituting the upper bottom wall and the lower top wall between the adjacent fourth and fifth conductor accommodating cavities. Similarly, the horizontal insertion tab 3 between the e column and the f column is horizontally inserted into the horizontal insertion slot 4 between the E column and the F column. The horizontal insertion tab 3 between the h column and the i column is horizontally inserted into the horizontal insertion slot 4 between the H column and the I column. The horizontal insertion tab 3 between the k column and the l column is horizontally inserted into the horizontal insertion slot 4 between the K column and the L column. The N column and the n column are 90° bent and overlapped to constitute the lower bottom end wall of the fifth conductor accommodating cavity.

[0069] Fixing between adjacent bottom walls and top walls of the five conductor accommodating cavities

[0070] The vertical insertion slot 5 between column A and column B and the vertical insertion tongue 6 between column C and column D are vertically inserted with each other, so that column B and column C are tightly contacted, the vertical insertion slot 5 between column a and column b on the opposite side and the vertical insertion tongue 6 between column c and column d are vertically inserted with each other, so that column b and column c are tightly contacted, and the insulation between the first and second conductor accommodating cavities is ensured; similarly, the vertical insertion slot 5 between column D and column E and the vertical insertion tongue 6 between column F and column G are vertically inserted with each other, the vertical insertion slot 5 between column d and column e and the vertical insertion tongue 6 between column f and column g are vertically inserted with each other, the vertical insertion slot 5 between column G and column H and the vertical insertion tongue 6 between column I and column J are vertically inserted with each other, the vertical insertion slot 5 between column g and column h and the vertical insertion tongue 6 between column i and column j are vertically inserted with each other, the vertical insertion slot 5 between column J and column K and the vertical insertion tongue 6 between column L and column M are vertically inserted with each other, and the vertical insertion slot 5 between column j and column k and the vertical insertion tongue 6 between column l and column m are vertically inserted with each other; and column B and column C, column b and column c, column E and column F, column e and column f, column H and column I, column h and column i, column K and column L, and column k and column l are fixed by adhesive bonding through the insulating paint, and a group of slot liners composed of five integrally connected conductor accommodating cavities are formed.

[0071] After the integrated bending preforming of the insulating paper 1, the insulating paper 1 is placed in the motor stator slot 71, and then the conductors are placed one by one into the conductor accommodating cavities 2 formed by the insulating paper 1, and after the shaping of the conductor end (outlet end), the insulating paint is dropped or immersed on the stator assembly of the flat wire motor, at this time, the gap between the integrated bending preformed insulating paper 1 and the conductor is filled and covered by the insulating paint.

[0072] The application not only does not require the motor to have an even number of layers of conductors, but also has the advantages of the B-type insulating paper structure, which can eliminate the gap at the corner of the S-type insulating paper structure; the amount of insulating paper is equivalent to that of the B-type insulating paper structure, which can avoid the difficulty in controlling the depth size of the middle layer of the B-type insulating paper structure, and simplify the process step difficulty during the embedding process; the insulating paper can be cut / prepared in advance according to the amount of insulating paper, and one piece of insulating paper can be used to complete the preparation of the stator slot liner in the slot by folding, which can complete the preparation of the stator slot liner in the slot without limiting the number of layers of conductors in the slot.

[0073] Example 3

[0074] An insulation paper structure for covering conductors in slots of an electric machine, which differs from the embodiment 2 in that the vertical insertion tabs 6 are cut at the left and right pairs of folded surfaces constituting the bottom wall of the upper conductor accommodation cavity 2 to the lower end of the left and right side walls to the lower folding lines 17; the vertical insertion slits 5 are cut at the left and right pairs of folded surfaces constituting the top wall of the lower conductor accommodation cavity 2 to the upper folding lines 18 corresponding to the positions of the vertical insertion tabs 6 of the upper conductor accommodation cavity 2, and the left and right vertical insertion tabs 6 of the upper conductor accommodation cavity 2 are respectively vertically inserted downward into the left and right vertical insertion slits 5 of the lower conductor accommodation cavity 2, and the outer surface of each vertical insertion tab 6 is in contact with the inner surface of the corresponding side wall.

[0075] Embodiment 4

[0076] Referring to Figure 7 shown, an insulation paper structure for covering conductors in slots of an electric machine, which differs from the embodiment 2 in that four groups of slot liners 11 are integrally connected horizontally, each group of slot liners 11 is integrally bent by the insulation paper 1 to surround five conductor accommodation cavities 2 adjacent to each other in the upper and lower directions; the horizontal insertion tabs 3 and the horizontal insertion slits 4 of every two adjacent slot liners 11 are arranged in reverse symmetry, and the vertical insertion tabs 6 and the vertical insertion slits 5 of every two adjacent slot liners are arranged in reverse symmetry.

[0077] Embodiment 5

[0078] Referring to Figure 8 shown, an insulation paper structure for covering conductors in slots of an electric machine, which differs from the embodiment 2 in that four groups of slot liners 11 are integrally connected horizontally, each group of slot liners 11 is integrally bent by the insulation paper 1 to surround five conductor accommodation cavities 2 adjacent to each other in the upper and lower directions; the horizontal insertion tabs 3 and the horizontal insertion slits 4 of every two adjacent slot liners 11 are arranged in symmetry, and the vertical insertion tabs 6 and the vertical insertion slits 5 of every two adjacent slot liners are arranged in symmetry.

[0079] Although the present application has been specifically shown and described with respect to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details can be made therein without departing from the spirit and scope of the application as defined in the appended claims.

Claims

1. An insulation paper structure for covering a slot conductor of an electric machine, characterized by: The insulating paper (1) is integrally bent to form at least two conductor accommodating cavities (2) which are adjacent to each other in upper and lower directions and constitute a group of slot liners (11); The first end (12) and the end (13) of the insulating paper (1) are bent to form the lower end walls of the conductor accommodating cavities, the upper and lower two bottom walls and the top wall between the two adjacent conductor accommodating cavities (2) are formed by inwardly bending the inner side walls of the insulating paper (1) and being fixed at the folding lines (14), the upper two folding surfaces (15) on the left and right sides constitute the bottom walls of the upper conductor accommodating cavities, and the lower two folding surfaces (16) on the left and right sides constitute the top walls of the lower conductor accommodating cavities; The fixing mode at the folding lines (14) where the insulating paper (1) is inwardly bent on the left and right sides is a mortise and tenon structure. A horizontal insertion tongue (3) is cut on the upper folding surface (15) or the lower folding surface (16) of the insulating paper (1) at the middle part of the folding line (14) on one side, and a horizontal insertion slot (4) is cut on the corresponding folding line (14) on the other side, the horizontal insertion tongue (3) on one side is inserted into the horizontal insertion slot (4) on the other side, and the upper and lower surfaces of the horizontal insertion tongue (3) are fixed between the upper and lower two folding surfaces of the folding line (14) where the horizontal insertion slot (4) is located.

2. An insulation paper structure for covering a conductor in a slot of an electric machine according to claim 1, characterized in that: The upper folding surface (15) and the lower folding surface (16) connected by the folding line (14) on one side of the folding surface which constitutes the bottom wall and the top wall of the adjacent conductor accommodating cavity (2) are adhesively fixed; the upper folding surface (15) and the lower folding surface (16) connected by the folding line (14) on the other side of the folding surface which constitutes the bottom wall and the top wall of the adjacent conductor accommodating cavity (2) are adhesively fixed.

3. An insulation paper structure for covering a conductor in a slot of an electric machine according to claim 1, characterized in that: A vertical insertion slot (5) is cut at the lower folding line (17) between the left and right side walls and the left and right two folding surfaces which constitute the bottom wall of the front or rear part of the upper conductor accommodating cavity (2); a vertical insertion tongue (6) is cut at the upper folding line (18) between the left and right two folding surfaces which constitute the top wall and the left and right side walls of the lower conductor accommodating cavity (2) corresponding to the position of the vertical insertion slot (5) of the upper conductor accommodating cavity (2), the left and right two vertical insertion tongues (6) of the lower conductor accommodating cavity (2) are vertically inserted into the left and right two vertical insertion slots (5) of the upper conductor accommodating cavity (2) in a corresponding manner, and the outer surface of each vertical insertion tongue (6) is in contact with the inner surface of the corresponding side wall.

4. An insulation paper structure for covering a conductor in a slot of an electric machine according to claim 1, characterized in that: The left and right pairs of fold surfaces constituting the bottom wall of the front or rear part of the upper conductor accommodating cavity (2) are respectively cut at the lower end of the left and right side walls to the lower fold line (17) of the vertical plug-in tongue (6); the left and right side walls of the lower conductor accommodating cavity (2) corresponding to the vertical plug-in tongue (6) of the upper conductor accommodating cavity (2) are respectively cut at the upper fold line (18) between the left and right pairs of fold surfaces constituting the top wall, and the vertical plug-in slot (5) is cut; the left and right vertical plug-in tongues (6) of the upper conductor accommodating cavity (2) are respectively downwardly vertically inserted into the left and right vertical plug-in slots (5) of the lower conductor accommodating cavity (2), and the outer surface of each vertical plug-in tongue (6) is in contact with the inner surface of the corresponding side wall.

5. An insulation paper structure for covering a conductor in a slot of an electric machine according to claim 1, characterized in that: The width of the horizontal plug-in tongue (3) is 1 / 2-1 of the width of the upper or lower fold surface (15) or (16) on which the horizontal plug-in tongue (3) is cut.

6. An insulation paper structure for covering a conductor in a slot of an electric machine according to claim 3, characterized in that: The height of the vertical plug-in tongue (6) is 1 / 3-1 of the width of the upper or lower fold surface (15) or (16) on which the vertical plug-in tongue (6) is cut.

7. An insulation paper structure for covering a conductor in a slot of an electric machine according to claim 1, characterized in that: The fixing mode of the fold line (14) corresponding to the inward bending of the left and right of the insulation paper (1) is adhesive fixing.

8. An insulation paper structure for covering a conductor in a slot of an electric machine according to claim 3, characterized in that: The horizontal integral connection is composed of several groups of groove liners (11), the setting structure of the horizontal plug-in tongue (3) and the horizontal plug-in slot (4) of the two adjacent groove liners (11) is symmetrical or anti-symmetrical, and the setting structure of the vertical plug-in tongue (6) and the vertical plug-in slot (5) of the two adjacent groove liners is symmetrical or anti-symmetrical.

Images