Flat wire motor injection molding stator

Abstract

The invention relates to a flat wire motor injection molding stator which comprises a stator core and a stator winding, a stator square groove is arranged in the stator core, the stator winding is arranged in the stator square groove, and the stator winding is formed by stacking a plurality of flat wire conductors. A first injection molding insulation protruding block, a second injection molding insulation protruding block and a plurality of third injection molding insulation protruding blocks are arranged in the stator square groove, the first injection molding insulation protruding block is located at the groove bottom of the stator square groove, the second injection molding insulation protruding block is located at the groove opening of the stator square groove, and the third injection molding insulation protruding blocks are distributed on the inner walls of the two sides of the stator square groove. The injection molding insulation protruding blocks extend out of the stator iron core in the axial direction of the stator, and a boss structure is formed on the axial end face of the stator iron core. And injection molding insulating grooves are formed in the two sides of the injection molding insulating convex block. Compared with the prior art, the invention has the advantages of cost reduction, paint layer protection, temperature rise reduction and the like.

Description

Technical Field

[0001] The invention relates to an injection-molded stator, in particular to an injection-molded stator of a flat wire motor. Background Art

[0002] Flat wire motors are widely used in high-end electric vehicles due to a series of advantages.

[0003] The stator of the flat wire motor needs to be equipped with a slot wall insulation device. In the prior art, the slot wall insulation device has a tooth-shaped configuration away from the slot wall. The number of tooth-shaped configurations can match the number of electrical conductors. The tooth-shaped configuration is configured to fix the position of at least one electrical conductor in each stator slot. The slot wall insulation device forms a gap through the tooth-shaped configuration. The gap is preferably designed as a fluid channel and is configured to guide the cooling fluid. However, this type of design has high requirements on the shape of the tooth-shaped configuration of the slot wall insulation device, which increases the difficulty of stator wire embedding and the paint film is easily damaged during the stator offline process.

[0004] In addition, the tooth configuration of the slot wall insulation device serves as the boundary of the electrical conductor, and the distance between the conductors in the slot is determined by the size of the tooth configuration. This method limits the slot filling rate of the motor, affects the temperature rise, and is not conducive to further improving the motor power.

[0005] Moreover, when applied to high-power motors, since there is no protection during the twisting process of the flat wire winding, the paint film is easily damaged when the flat wire conductor is twisted, affecting the safety of the motor. Summary of the invention

[0006] The purpose of the present invention is to provide a flat wire motor injection molded stator that can solve the above-mentioned defects of the prior art.

[0007] The purpose of the present invention can be achieved by the following technical solutions:

[0008] A flat wire motor injection molded stator comprises a stator core and a stator winding, wherein a stator square slot is provided in the stator core, the stator winding is arranged in the stator square slot, and the stator winding is formed by stacking a plurality of flat wire conductors, and a first injection molded insulating protrusion, a second injection molded insulating protrusion and a plurality of third injection molded insulating protrusions are provided in the stator square slot, wherein the first injection molded insulating protrusion is located at the slot bottom of the stator square slot, the second injection molded insulating protrusion is located at the slot opening of the stator square slot, and the third injection molded insulating protrusions are distributed on the inner walls on both sides of the stator square slot, and the first injection molded insulating protrusion, the second injection molded insulating protrusion and the third injection molded insulating protrusion extend along the stator axial direction to the outside of the stator core, and form a boss structure at the axial end surface of the stator core;

[0009] A third injection-molded insulating groove is provided between adjacent third injection-molded insulating protrusions, a first injection-molded insulating groove is provided on both sides of the first injection-molded insulating protrusion, and a second insulating injection-molded groove is provided on both sides of the second injection-molded insulating protrusion.

[0010] In the stator square slot, the number of the third injection-molded insulating protrusions is twice the number of the flat wire conductors, which are evenly distributed on the inner walls on both sides of the stator square slot, and each third injection-molded insulating protrusion corresponds to and is aligned with each flat wire conductor.

[0011] In a radial cross section of the stator, a width of a side of the third injection-molded insulating protrusion contacting the flat-wire conductor is smaller than a width of a side surface of the flat-wire conductor.

[0012] In a radial cross section of the stator, a width of a side of the first injection-molded insulating protrusion contacting the flat wire conductor is smaller than a width of a bottom surface of the flat wire conductor.

[0013] In the radial cross section of the stator, the width of the side of the second injection-molded insulating protrusion contacting the flat wire conductor is smaller than the width of the bottom surface of the flat wire conductor.

[0014] In the radial cross section of the stator, the first injection-molded insulating protrusion, the second injection-molded insulating protrusion and the third injection-molded insulating protrusion are all boss-shaped, and the bottom surfaces are arranged closely against the slot wall of the square slot of the stator.

[0015] The surface of the boss structure is in an arc shape.

[0016] The first injection-molded insulating protrusion, the second injection-molded insulating protrusion and the third injection-molded insulating protrusion extend along the axial direction of the stator to near the outer wall of the stator core and are inclined toward the slot wall direction of the stator square slot.

[0017] The first injection-molded insulating protrusion, the second injection-molded insulating protrusion, the third injection-molded insulating protrusion, the first injection-molded insulating groove, the second injection-molded insulating groove and the third injection-molded insulating groove are made of the same material and are integrally injection-molded.

[0018] The flat wire conductor is an enameled copper flat wire.

[0019] Compared with the prior art, the present invention has the following beneficial effects:

[0020] 1. The injection-molded insulation layer is set to a form of unequal thickness, wherein the injection-molded insulation protrusion is aligned with the flat wire conductor and provides good support for it, and the insulation injection-molded grooves at both ends are used to provide a certain gap, which can save materials on the one hand, and enhance the fluidity of the insulating impregnating varnish on the other hand, thereby avoiding damage to the surface paint layer of the stator winding during assembly.

[0021] 2. The boss structure formed at the axial end face of the stator core is utilized to provide protection during the twisting process of the flat wire conductor, while effectively fixing the position of the injection-molded insulation structure, thereby enhancing the safety and stability of the flat wire motor during operation.

[0022] 3. The arc-shaped boss structure is adopted to guide the flat wire conductor to turn smoothly.

[0023] 4. The injection-molded insulating protrusion extends along the stator axis to the outer wall of the stator core and is inclined toward the slot wall of the stator square slot, which can guide the flat wire conductor to turn in advance, thereby reducing copper loss and lowering temperature rise. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a partial schematic diagram of a radial cross section of a stator of the present invention;

[0025] Figure 2 Schematic diagram of a single stator square slot;

[0026] Figure 3 is a schematic diagram of the stator end face;

[0027] Wherein: 1. stator core, 2. stator square slot, 3. flat wire conductor, 4. slot wall, 5. slot bottom, 6. slot mouth, 7. third injection molded insulating protrusion, 8. third injection molded insulating groove, 9. first injection molded insulating protrusion, 10. first injection molded insulating groove, 11. second injection molded insulating protrusion, 12. second insulating injection molded groove, 13. narrow side of flat wire conductor, 14. wide side of flat wire conductor, 15. stator end face, 16. boss structure, 17. gap, A1. end face of the third injection molded insulating protrusion, A2. end face of the first injection molded insulating protrusion, A3. end face of the second injection molded insulating protrusion, A4. surface of the boss structure, A5. bottom surface of the boss structure. DETAILED DESCRIPTION

[0028] The present invention is described in detail below in conjunction with the accompanying drawings and specific embodiments. This embodiment is implemented based on the technical solution of the present invention, and provides a detailed implementation method and specific operation process, but the protection scope of the present invention is not limited to the following embodiments.

[0029] A flat wire motor injection molded stator, such as Figure 1 and Figure 2As shown, it includes a stator core 1 and a stator winding, wherein a plurality of stator square slots 2 are arranged in the stator core 1, and the stator winding is arranged in the stator square slot 2, and the stator winding is formed by stacking a plurality of flat wire conductors 3, and the flat wire conductor 3 is an enameled copper flat wire, so the obtained stator winding is an enameled wire, and a first injection-molded insulating protrusion 9, a second injection-molded insulating protrusion 11 and a plurality of third injection-molded insulating protrusions 7 are arranged in the stator square slot 2, the first injection-molded insulating protrusion 9 is located at the slot bottom 5 of the stator square slot 2, the second injection-molded insulating protrusion 11 is located at the slot opening 6 of the stator square slot 2, and the third injection-molded insulating protrusion 7 is distributed on the inner walls of both sides of the stator square slot 2, and as shown in FIG. Figure 3 As shown, the first injection-molded insulating protrusion 9, the second injection-molded insulating protrusion 11 and the third injection-molded insulating protrusion 7 extend along the stator axial direction to the outside of the stator core 1, and form a boss structure 16 at the axial end surface of the stator core 1;

[0030] A third injection-molded insulating groove 8 is provided between adjacent third injection-molded insulating protrusions 7 , a first injection-molded insulating groove 10 is provided on both sides of the first injection-molded insulating protrusion 9 , and a second injection-molded insulating groove 12 is provided on both sides of the second injection-molded insulating protrusion 11 .

[0031] The injection-molded insulation layer is arranged in a form of unequal thickness, wherein the injection-molded insulation protrusions are aligned with the flat wire conductor and provide good support for it, and a certain gap 17 is provided by utilizing the insulation injection-molded grooves at both ends. This can save materials on the one hand, and enhance the fluidity of the insulating impregnating varnish on the other hand, thereby avoiding damage to the surface varnish layer of the stator winding during assembly.

[0032] Furthermore, the boss structure 16 formed at the axial end face of the stator core 1 is utilized to provide protection during the twisting process of the flat wire conductor 3 , while effectively fixing the position of the injection-molded insulating structure, thereby enhancing the safety and stability of the flat wire motor during operation.

[0033] The first injection-molded insulating protrusion 9 , the second injection-molded insulating protrusion 11 , the third injection-molded insulating protrusion 7 , the first injection-molded insulating groove 10 , the second injection-molded insulating groove 12 and the third injection-molded insulating groove 8 are made of the same material and are integrally injection-molded, and are all in full contact with the slot wall 4 of the stator square slot 2 .

[0034] In the stator square slot 2, the number of the third injection-molded insulating protrusions 7 is twice the number of the flat wire conductors 3, and they are evenly distributed on the inner walls of both sides of the stator square slot 2, and each third injection-molded insulating protrusion 7 corresponds to and aligns with each flat wire conductor 3, so that a relatively stable support can be achieved. And the thickness of the third injection-molded insulating groove 8 is less than the thickness of the third injection-molded insulating protrusion 7. Similarly, the thickness of the first injection-molded insulating groove 10 is less than the thickness of the first injection-molded insulating protrusion 9, and the thickness of the second insulation injection-molded groove 12 is less than the thickness of the second injection-molded insulating protrusion 11.

[0035] In the radial cross section of the stator, the width of the side of the third injection-molded insulating protrusion 7 contacting the flat-wire conductor 3 is smaller than the width of the side surface of the flat-wire conductor 3. Specifically, Figure 1 As shown, the radial length of the end faces A1 of the third injection-molded insulating protrusions 7 on both sides parallel to the slot wall 4 is preferably set to be no greater than the length of the narrow side of the flat-wire conductor 3 .

[0036] Only one first injection-molded insulating protrusion 9 is provided in a stator square slot 2. In the radial cross section of the stator, the width of the side of the first injection-molded insulating protrusion 9 contacting the flat wire conductor 3 is smaller than the width of the bottom surface of the flat wire conductor 3, that is, the circumferential length of the end face A2 of the first injection-molded insulating protrusion parallel to the slot bottom is preferably set to be no greater than the length of the flat wire conductor wide side 14 of the flat wire conductor 3.

[0037] Only one second injection-molded insulating protrusion 11 is provided in a stator square slot 2. In the radial cross-section of the stator, the width of the side of the second injection-molded insulating protrusion 11 contacting the flat wire conductor 3 is smaller than the width of the bottom surface of the flat wire conductor 3, that is, the circumferential length of the end face A3 of the second injection-molded insulating protrusion parallel to the slot is preferably set to be no greater than the length of the wide side 14 of the flat wire conductor 3.

[0038] The above settings are conducive to further improving the slot fill rate of the flat wire motor and improving the power density of the flat wire motor. The injection-molded insulation structure of the inner wall of the stator square slot 2 adopts overall unequal thickness injection molding, and the injection-molded insulation protrusions are in full contact with the flat wire conductor 3. Compared with the equal thickness plastic coating of the inner wall of the stator square slot, the effective heat conduction area in full contact with the flat wire conductor 3 is not significantly reduced, and the total heat conduction area is increased, which can efficiently transfer the heat of the flat wire conductor 3 to the stator core 1, and save injection molding insulation materials and motor production costs. Several injection-molded insulation protrusions in the stator square slot 2 can play a role in fixing the flat wire conductor 3 in the slot, enhance the stability of the motor, and improve the NVH performance of the motor.

[0039] In the radial cross section of the stator, the first injection-molded insulating protrusion 9 , the second injection-molded insulating protrusion 11 and the third injection-molded insulating protrusion 7 are all boss-shaped, and the bottom surfaces are arranged closely against the slot wall 4 of the stator square slot 2 .

[0040] like Figure 3As shown, the surface of the boss structure 16 is in an arc shape. The use of the arc-shaped boss structure 16 can guide the flat wire conductor 3 to turn smoothly. Specifically, the surface A4 of the boss structure of the boss structure 16 is a smooth curved surface, and the boss area close to the stator end face 15 is large, which strengthens the stability of the injection molded insulation structure. The boss-shaped injection molded insulation structure on the stator end face 15 can protect the paint film of the flat wire conductor 3 from being scratched by the iron core 1 during the turning process, thereby enhancing the safety and reliability of the motor operation. The injection molded insulation structure forms a boss structure 16 on the two stator end faces 15 of the stator, and the bottom surface A5 of the boss structure is relatively large. This structure fixes the position of the injection molded insulation structure, enhances the mechanical stability, and enables it to be axially displaced without being affected by the production operation. At the same time, the injection molded insulation structure will not be severely deformed due to the extrusion during the turning process of the flat wire conductor, and can play an effective insulation protection role for the flat wire conductor. In addition, the curved boss injection-molded insulation structure with a smooth surface transition is conducive to lowering the starting position of the flat wire conductor twisting process, which can effectively shorten the end length of the flat wire conductor, further reduce the temperature rise of the motor, and improve the power density.

[0041] The first injection-molded insulating protrusion 9, the second injection-molded insulating protrusion 11 and the third injection-molded insulating protrusion 7 extend along the stator axial direction to the outer wall of the stator core 1 and are inclined toward the slot wall 4 of the stator square slot 2, which can guide the flat wire conductor 3 to turn in advance, thereby reducing copper loss and lowering temperature rise.

[0042] In addition, a gap 17 is formed between the first injection molding insulating groove 10, the second injection molding insulating groove 12 and the third injection molding insulating groove 8 in the slot and the flat wire conductor 3, as shown in FIG. Figure 1 and Figure 2 As shown. After the stator is varnished, the position of the flat wire conductor 3 in the slot is further fixed, and the insulation performance of the motor is enhanced. The fluidity of the insulating varnish in the gap 17 is better, and the amount of varnish on the flat wire conductor 3 is more, which can further enhance the insulation effect in the slot. There is no special description of the insulating varnish, and an insulating varnish with good insulation effect and high thermal conductivity is preferred.

Claims

1. A flat wire motor injection molded stator, comprising a stator core (1) and a stator winding, wherein the stator core (1) is provided with a stator square slot (2), the stator winding is arranged in the stator square slot (2), and the stator winding is formed by stacking a plurality of flat wire conductors (3), characterized in that: The stator square slot (2) is provided with a first injection-molded insulating protrusion (9), a second injection-molded insulating protrusion (11) and a plurality of third injection-molded insulating protrusions (7); the first injection-molded insulating protrusion (9) is located at the bottom of the stator square slot (2); the second injection-molded insulating protrusion (11) is located at the slot opening of the stator square slot (2); the third injection-molded insulating protrusions (7) are distributed on the inner walls on both sides of the stator square slot (2); and the first injection-molded insulating protrusion (9), the second injection-molded insulating protrusion (11) and the third injection-molded insulating protrusion (7) extend along the stator axial direction to the outside of the stator core (1), and form a boss structure (16) at the axial end surface of the stator core (1); A third injection-molded insulating groove (8) is provided between adjacent third injection-molded insulating protrusions (7), first injection-molded insulating grooves (10) are provided on both sides of the first injection-molded insulating protrusion (9), and second injection-molded insulating grooves (12) are provided on both sides of the second injection-molded insulating protrusion (11).

2. The flat wire motor injection molded stator according to claim 1, characterized in that: In the stator square slot (2), the number of the third injection-molded insulating protrusions (7) is twice the number of the flat wire conductors (3), and they are evenly distributed on the inner walls on both sides of the stator square slot (2), and each third injection-molded insulating protrusion (7) corresponds to and is aligned with each flat wire conductor (3) one by one.

3. A flat wire motor injection molded stator according to claim 1 or 2, characterized in that: In the radial cross section of the stator, the width of the side of the third injection-molded insulating projection (7) contacting the flat-wire conductor (3) is smaller than the width of the side surface of the flat-wire conductor (3).

4. The flat wire motor injection molded stator according to claim 1, characterized in that: In the radial cross section of the stator, the width of the side of the first injection-molded insulating protrusion (9) contacting the flat wire conductor (3) is smaller than the width of the bottom surface of the flat wire conductor (3).

5. The flat wire motor injection molded stator according to claim 1, characterized in that: In the radial cross section of the stator, the width of the side of the second injection-molded insulating protrusion (11) contacting the flat wire conductor (3) is smaller than the width of the bottom surface of the flat wire conductor (3).

6. The flat wire motor injection molded stator according to claim 1, characterized in that: In the radial cross section of the stator, the first injection-molded insulating protrusion (9), the second injection-molded insulating protrusion (11) and the third injection-molded insulating protrusion (7) are all boss-shaped, and the bottom surfaces are arranged in close contact with the slot wall (4) of the stator square slot (2).

7. The flat wire motor injection molded stator according to claim 1, characterized in that: The surface of the boss structure (16) is in an arc shape.

8. The flat wire motor injection molded stator according to claim 1, characterized in that: The first injection-molded insulating protrusion (9), the second injection-molded insulating protrusion (11) and the third injection-molded insulating protrusion (7) extend along the stator axial direction to the outer wall of the stator core (1) and are inclined in the direction of the slot wall (4) of the stator square slot (2).

9. The flat wire motor injection molded stator according to claim 1, characterized in that: The first injection-molded insulating protrusion (9), the second injection-molded insulating protrusion (11), the third injection-molded insulating protrusion (7), the first injection-molded insulating groove (10), the second injection-molded insulating groove (12) and the third injection-molded insulating groove (8) are made of the same material and are integrally injection-molded.

10. The flat wire motor injection molded stator according to claim 1, characterized in that: The flat wire conductor (3) is an enameled copper flat wire.

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