Interphase insulation sheets, motor stators and motors

Abstract

The present invention provides an interphase insulating sheet material, which is used to be arranged between two radially adjacent windings of the stator core of a motor, and the interphase insulating sheet material includes a main body and two lugs, the main body having an opening and being in an arched shape, the lugs being connected to the inner side of the end of the main body in a manner facing the opening, and the lugs being used to be bonded to the windings. The interphase insulating material according to the present invention has good insulation effect and high reliability, and is not prone to displacement, misalignment, falling off and damage. The motor stator and the motor according to the present invention have good insulation effect and are simple to manufacture.

Description

Technical Field

[0001] The present invention relates to the field of motors, and more particularly to an interphase insulating sheet for interphase insulation of a motor stator winding, a motor stator comprising the interphase insulating sheet, and a motor comprising the motor stator. Background Art

[0002] Taking the motor of new energy vehicles as an example, the stator of the motor is wound with three-phase windings (U-phase winding, V-phase winding and W-phase winding) one by one, and the part of each phase winding protruding from the stator slot forms a coil. In order to ensure the insulation performance of the winding, insulating sheets (also called interphase insulating paper) are provided between adjacent different phase windings.

[0003] Generally, the order of setting the winding and the interphase insulation paper is: embedding the U-phase winding, arranging the interphase insulation paper between the U-phase and the V-phase, expanding the U-phase wire package, embedding the V-phase winding, arranging the interphase insulation paper between the V-phase and the W-phase, expanding the V-phase wire package, and embedding the W-phase winding. After that, it is usually necessary to use binding wire to bind the three-phase windings at each axial end of the stator together.

[0004] In the above process, the expansion of the wire package, the embedding of the winding and the bundling in the subsequent process may affect the interphase insulation paper arranged in the previous process, for example, causing the interphase insulation paper set in the previous process to shift or even fall off. Summary of the invention

[0005] The purpose of the present invention is to overcome or at least alleviate the deficiencies of the above-mentioned prior art, and to provide an interphase insulating sheet material which is easy to fix, not prone to displacement and has good insulation effect, a motor stator including the interphase insulating material, and a motor including the motor stator.

[0006] According to a first aspect of the present invention, there is provided an interphase insulating sheet material for being arranged between two radially adjacent coils of a stator core of a motor, wherein:

[0007] The interphase insulating sheet comprises a main body and two lugs.

[0008] The main body has an opening and is in an arcuate shape.

[0009] The lug portion is connected to the inner side of the end portion of the main body portion in a manner facing the opening.

[0010] The lug portion is used for bonding to the wire package.

[0011] In at least one embodiment, a surface of the interphase insulation sheet facing the wire package is adhesive at least at the lug portion.

[0012] In at least one embodiment, the entire surface of the interphase insulation sheet facing the wire package is adhesive.

[0013] In at least one embodiment, when the interphase insulating sheet is arranged with the opening facing the end of the motor stator, the maximum height of the opening in the axial direction of the motor stator is at least 90% of the hole height of the middle hollow part of the coil.

[0014] In at least one embodiment, when the interphase insulating sheet is arranged with the opening facing the end of the motor stator, in the axial direction of the motor stator, the interphase insulating sheet exceeds the coil by no more than 50% of the maximum height of the opening.

[0015] In at least one embodiment, both sides of an end portion of the main body opposite to the opening are rounded.

[0016] In at least one embodiment, the interphase insulating sheet is made of glass cloth tape.

[0017] According to a second aspect of the present invention, a motor stator is provided, comprising a stator core and a three-phase winding, wherein the winding forms a coil at an end of the stator core, wherein:

[0018] The motor stator further comprises the interphase insulating sheet according to the first aspect of the present invention, and the interphase insulating sheet is arranged between at least two coils of different phases that are adjacent in the radial direction.

[0019] In at least one embodiment, the lug portion of the interphase insulation sheet at least partially surrounds the winding package and is connected to a root portion of the winding package close to the stator core.

[0020] According to a third aspect of the present invention, there is provided a motor for use in a new energy vehicle, wherein the motor comprises a motor stator according to the second aspect of the present invention.

[0021] The interphase insulating material according to the present invention can completely isolate the winding phases, has good insulation effect, high reliability, and is not prone to displacement, misalignment, falling off and damage. The motor stator and motor according to the present invention have good insulation effect and are easy to manufacture. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a schematic diagram of a motor stator observed along the axial direction according to one embodiment of the present application.

[0023] Figure 2 It is a schematic diagram of unfolding an interphase insulation sheet according to one embodiment of the present application.

[0024] Figure 3 A schematic diagram of the outline of the interphase insulating sheet and the wire package during the assembly process according to one embodiment of the present application is shown.

[0025] Figure 4 A schematic diagram of the interphase insulating sheet and the wire package during the assembly process according to one embodiment of the present application is shown.

[0026] Description of reference numerals:

[0027] SC stator core; 10 interphase insulating sheet; 11 main body; 11a fillet; 12 lug; 10a opening;

[0028] 20 wire package; 20a root; 21U phase wire package; 22V phase wire package; 23W phase wire package;

[0029] A is axial; R is radial; C is circumferential. DETAILED DESCRIPTION

[0030] The exemplary embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood that these specific descriptions are only used to teach those skilled in the art how to implement the present invention, and are not intended to exhaust all possible modes of the present invention, nor to limit the scope of the present invention.

[0031] Reference Figures 1 to 4 , introduces an interphase insulation sheet and a motor stator according to an embodiment of the present application.

[0032] Unless otherwise specified, refer to Figure 1 and Figure 2 , A represents the axial direction of the motor stator, R represents the radial direction of the motor stator, and C represents the circumferential direction of the motor stator.

[0033] Reference Figure 1 The motor stator of this embodiment includes a stator core SC, a winding wound on the stator core SC, and an interphase insulating sheet 10 arranged between the windings. From the radial outside to the radial inside, the three-phase windings are U-phase winding, V-phase winding, and W-phase winding. The winding is partially embedded in the slot of the stator core SC and partially protrudes from the end of the stator core SC to form a U-shaped coil 20. Figure 1 It can be seen that each phase winding forms multiple coils 20 at one end of the stator, which are U-phase coil 21, V-phase coil 22 and W-phase coil 23.

[0034] The purpose of providing the interphase insulating sheet 10 is to enhance the insulation capacity between adjacent wire packages 20 of different phases. Figure 1 The state where the interphase insulating sheet 10 is provided between the V-phase wire package 22 and the W-phase wire package 23 is shown.

[0035] Reference Figures 2 to 4The interphase insulating sheet 10 has a shape substantially similar to the wire package 20. Specifically, the interphase insulating sheet 10 includes a main body portion 11 and two lug portions 12.

[0036] The main body 11 is in an arch shape, and its concave portion forms an opening 10a. The outer contour of the main body 11 is similar to the outer contour of the wire package 20, and preferably, the outer contour of the main body 11 is slightly larger than the wire package 20, so that the inner side of the V-phase wire package 22 facing the W-phase wire package (also refer to Figure 1 ) can be covered by the main body 11.

[0037] The setting of the opening 10a, on the one hand, enables the main body 11 to better adapt to the shape of the wire bundle 20 and form a better fit with the wire bundle 20; on the other hand, it is to avoid the interference of subsequent binding operations on the setting position of the interphase insulating sheet 10, so that when the binding rope passes through the wire bundle, it is not easy to pull the interphase insulating sheet 10 and cause the interphase insulating sheet 10 to shift or damage.

[0038] Optionally, refer to Figure 3 When the interphase insulating sheet 20 is arranged with the opening 10a facing the end of the motor stator, in the axial direction A of the motor stator, the excess dimension d of the main body 11 beyond the coil 20 is not greater than 50% of the maximum height H1 of the opening 10a.

[0039] Optionally, when the interphase insulating sheet 20 is arranged with the opening 10 a facing the end of the motor stator, in the axial direction A of the motor stator, the excess dimension d of the main body portion 11 beyond the coil 20 is not greater than 20 mm.

[0040] Optionally, when the interphase insulating sheet 20 is arranged with the opening 10a facing the end of the motor stator, in the axial direction A of the motor stator, the maximum height H1 of the opening 10a is at least 90% of the hole height H2 of the middle hollow portion of the coil 20 .

[0041] Optionally, in the case where the interphase insulating sheet 20 is disposed with the opening 10a facing the end of the motor stator, the maximum height H1 of the opening 10a in the axial direction A of the motor stator is at least 10 mm.

[0042] The design of the above-mentioned contour shape and size of the main body 11, on the one hand, enables the main body 11 to effectively cover the wire package 20; on the other hand, it prevents the main body 11 from extending too far beyond the wire package 20 to interfere with other components, so as to cause the arranged phase-to-phase insulating sheet 20 to shift, be damaged or even fall off during the operation of subsequent processes.

[0043] The lug 12 is connected to the inner side of the end of the main body 11 near the opening 10a. After being folded back, the lug 12 is attached to the root 20a in a manner of at least partially surrounding the root 20a of the wire package 20. This arrangement is based on the consideration that if the interphase insulating sheet 10 is displaced due to the influence of subsequent processes, the first area to be displaced is the area near the root 20a of the wire package 20. This embodiment strengthens and fixes this area, thereby effectively preventing the interphase insulating sheet 10 from being displaced.

[0044] The location of the lug 12 also has the advantage of being convenient for folding. The lug 12 is arranged on the inner side of the wire package 20 and partially surrounds the root 20a after being folded through the opening 10a, rather than being folded through the outer side of the wire package 20. This is because the opening 10a provides an effective space for the folding operation of the lug 12; and the outer side of the wire package 20 is close to other adjacent wire packages, which is inconvenient for the operator to operate. Therefore, the lug 12 of this embodiment may not extend and fold to the outer side of the wire package 20.

[0045] Optionally, in the circumferential direction C, the length of the lug portion 12 does not exceed the width of the root 20a of the coil 20. That is, after the lug portion 12 is folded back, it only surrounds the root 20a of the coil 20 of the phase, and does not extend to other areas, and is not easy to interfere with other components.

[0046] Optionally, an adhesive is provided on the surface of the lug portion 12 facing the wire bundle 20 to facilitate the fixation of the lug portion 12 and the root portion 20 a.

[0047] Optionally, an adhesive is provided on the surface of the entire interphase insulation sheet 10 facing the wire bundle 20 , so that the interphase insulation sheet 10 as a whole can be better fixed to the wire bundle 20 .

[0048] Optionally, the entire interphase insulating sheet 10 is a glass cloth tape.

[0049] The present invention has at least one of the following advantages:

[0050] (i) The interphase insulating sheet 10 of the present invention can effectively insulate adjacent interphase coils and is not likely to interfere with other components of the stator or tools in the assembly process, and is not likely to shift, misalign, break or even fall off.

[0051] (ii) The opening 10a is provided with a lug 12 that can be fixed to the root 20a of the coil 20, so that the interphase insulating sheet 10 is reinforced and fixed at the weak point of the connection. Moreover, the location of the lug 12 makes it easy to fix the lug 12.

[0052] Of course, the present invention is not limited to the above-mentioned embodiments, and those skilled in the art can make various modifications to the above-mentioned embodiments of the present invention under the guidance of the present invention without departing from the scope of the present invention. For example:

[0053] (i) The present application does not impose any restrictions on the specific winding method of the stator windings. As long as the three-phase windings are wound successively in the radial direction of the stator core, the interphase insulating sheet 10 according to the present application is applicable.

[0054] (ii) The present application does not limit the specific material composition of the interphase insulating sheet. For example, in other possible embodiments, the interphase insulating material may not have a backing adhesive, and it may be any insulating paper in the prior art, such as mica paper, aramid fiber paper, polyester fiber non-woven fabric, and insulating film. For another example, in the case where the interphase insulating sheet has a backing adhesive, it is also possible not to use glass cloth tape, but to add adhesive to the back of any insulating paper in the prior art.

[0055] (iii) The motor stator according to the present application may be provided with the interphase insulating sheet according to the present application only between some of the windings, while interphase insulating materials of different forms may be provided between other windings.

Claims

1. An interphase insulating sheet material, which is used to be arranged between two coils (20) adjacent in the radial direction (R) of a stator core (SC) of a motor, It is characterized in that The interphase insulating sheet comprises a main body portion (11) and two lug portions (12). The main body (11) has an opening (10a) and is in an arcuate shape, and the interphase insulating sheet is used to be arranged in a manner that the opening (10a) faces the end of the motor stator. The lug portion (12) is connected to the inner side of the end portion of the main body portion (11) in a manner facing the opening (10a). The lug portion (12) is used to be folded back through the opening (10a) and then bonded to the wire package (20) in a manner of at least partially surrounding the root portion (20a) of the wire package (20). In the circumferential direction, the length of the lug portion (12) does not exceed the width of the root portion (20a) of the wire package (20).

2. The interphase insulating sheet according to claim 1, It is characterized in that The surface of the interphase insulating sheet facing the wire package (20) is adhesive at least at the lug portion (12).

3. The interphase insulating sheet according to claim 1, It is characterized in that The entire surface of the interphase insulating sheet facing the wire package (20) is adhesive.

4. The interphase insulating sheet according to claim 1, It is characterized in that When the interphase insulating sheet is arranged with the opening (10a) facing the end of the motor stator, in the axial direction (A) of the motor stator, the maximum height (H1) of the opening (10a) is at least 90% of the hole height (H2) of the middle hollow part of the coil (20).

5. The interphase insulating sheet according to claim 1, It is characterized in that When the interphase insulating sheet is arranged with the opening (10a) facing the end of the motor stator, in the axial direction (A) of the motor stator, the excess dimension (d) of the interphase insulating sheet beyond the coil (20) is no greater than 50% of the maximum height (H1) of the opening (10a).

6. The interphase insulating sheet according to claim 1, It is characterized in that Rounded corners (11a) are formed on both sides of an end portion of the main body (11) opposite to the opening (10a).

7. The interphase insulating sheet according to any one of claims 1 to 6, It is characterized in that The material of the interphase insulating sheet is glass cloth tape.

8. A motor stator, comprising a stator core (SC) and a three-phase winding, wherein the winding forms a coil (20) at an end of the stator core (SC). It is characterized in that The motor stator further comprises an interphase insulating sheet (10) according to any one of claims 1 to 7, wherein the interphase insulating sheet (10) is disposed between at least two coils (20) of different phases that are adjacent in the radial direction (R).

9. The motor stator according to claim 8, It is characterized in that The lug portion (12) of the interphase insulating sheet (10) at least partially surrounds the winding package (20) and is connected to a root portion (20a) of the winding package (20) close to the stator core (SC).

10. A motor for new energy vehicles, It is characterized in that The electric machine comprises an electric machine stator according to claim 8 or 9.

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