Shell and stator integrated forming structure of high-speed motor and forming method of shell and stator integrated forming structure

Abstract

The invention discloses a shell and stator integrated molding structure of a high-speed motor and a molding method thereof.The shell and stator integrated molding structure of the high-speed motor comprises a stator component, a wire protection cover, a bearing chamber insert and a plastic shell, a plurality of coils are arranged on the stator component in the circumferential direction, and the coils define an assembly cavity; the assembling cavity extends along the length direction of the stator component; the wire protecting cover covers the end surface of the stator component and is used for covering the coil; a via hole is formed in the wire protecting cover and is opposite to the inlet of the assembly cavity; the bearing chamber insert is arranged on one side, deviating from the stator component, of the wire protecting cover; an assembly chamber is arranged on the bearing chamber insert; the assembling chamber, the via hole and the assembling cavity are sequentially communicated, are coaxially arranged and are used for assembling a rotor of the high-speed motor; the plastic shell is integrally formed on the end face of the stator component, the outer circle face of the wire protecting cover and the outer circle face of the bearing chamber insert in an injection molding mode. And the processing flow is simplified and the product structure is optimized by utilizing an integrated forming mode, so that heat dissipation and performance improvement are facilitated.

Description

Technical Field

[0001] The present invention relates to the technical field of high-speed motors, and in particular to an integrated molding structure of a housing and a stator of a high-speed motor and a molding method thereof. Background Art

[0002] High-speed motors have the advantages of high transmission efficiency, low noise, and fast dynamic response, and have broad application prospects in aerospace, flywheel energy storage, household appliances, etc. During the operation of high-speed motors, the rotor speed is high, generally exceeding 100,000 revolutions per minute, so it is easy to heat up. For this reason, existing high-speed motors are equipped with air ducts on the outside of the casing and equipped with blades for blowing to achieve the effect of accelerating heat dissipation.

[0003] However, in the current process of installing the casing outside the stator and rotor of the motor, it is necessary to fix them by gluing, and the uniformity of the gluing is difficult to control; a gap needs to be left for casing assembly during the processing, so the production precision is insufficient; in order to facilitate the heat dissipation of the high-speed motor, the thickness of the casing on the stator and rotor needs to be reduced as much as possible, so it is difficult to process and assemble; and as the structural design of high-speed motors is gradually miniaturized, the difficulty of assembly operations is further increased, and the performance and service life of the product cannot be guaranteed, affecting the final production yield of the product.

[0004] Therefore, the prior art still needs to be improved and developed. Summary of the invention

[0005] In view of the above-mentioned deficiencies in the prior art, the purpose of the present invention is to provide an integrated molding structure of the casing and stator of a high-speed motor and a molding method thereof, aiming to solve the problems of the existing high-speed motors due to the difficulty of assembly operation, the inability to guarantee product performance, the reduced service life and the insufficient production yield.

[0006] The technical solution of the present invention is as follows:

[0007] A high-speed motor housing and stator integrated molding structure, which includes a stator component, a wire protection cover, a bearing chamber insert and a plastic shell, wherein the stator component is circumferentially arranged with a plurality of coils, the plurality of coils enclose an assembly cavity, and the assembly cavity extends along the length direction of the stator component; the wire protection cover is covered on the end surface of the stator component for covering the coils; a through hole is formed on the wire protection cover at a position opposite to the entrance of the assembly cavity; the bearing chamber insert is arranged on a side of the wire protection cover away from the stator component; an assembly chamber is arranged on the bearing chamber insert; the assembly chamber, the through hole and the assembly cavity are sequentially connected and coaxially arranged for assembling the rotor of the high-speed motor; the plastic shell is integrally injection molded on the end surface of the stator component, the outer circumferential surface of the wire protection cover and the outer circumferential surface of the bearing chamber insert.

[0008] The shell and stator of the high-speed motor are integrated into a structure, wherein the plastic shell includes an inner ring connecting part, an outer ring connecting part and a plurality of air guide plates, the inner ring connecting part is connected to the stator component, and is nested on the outer circumferential surface of the wire protection cover and the outer circumferential surface of the bearing chamber insert; a plurality of air guide plates are arranged in a ring shape on the outside of the inner ring connecting part; the outer ring connecting part is sleeved on the outside of the inner ring connecting part and connected to the air guide plates; two adjacent air guide plates and the inner ring connecting part and the outer ring connecting part together constitute an air duct.

[0009] The housing and stator of the high-speed motor are integrally formed, wherein the outer cylindrical surface of the inner ring connecting portion is flush with the outer cylindrical surface of the stator component; one end of the air guide plate is arranged on the outer cylindrical surface of the inner ring connecting portion, and the other end extends toward the stator component and contacts with the outer cylindrical surface of the stator component.

[0010] The housing and stator of the high-speed motor are integrally formed, wherein the aperture of the via hole is less than or equal to the diameter of the radial cross section of the assembly cavity; and the aperture of the via hole is greater than the diameter of the radial cross section of the assembly chamber.

[0011] The housing and stator of the high-speed motor are integrally formed, wherein the stator component includes a stator core and a rubber-coated bracket, the stator core is annular in shape, and a plurality of winding teeth are protruded on the inner circumferential surface of the stator core; the rubber-coated bracket is nested on the stator core; the rubber-coated bracket includes an annular main body arranged to fit the inner circumferential surface of the stator core, a winding portion connected to the annular main body and wrapping the winding teeth, and an arc-shaped retaining wall connected to the winding portion; the winding portion is used to wind the enameled wire to form the coil, the arc-shaped retaining wall is arranged on one end of the winding portion away from the annular main body, and a plurality of the arc-shaped retaining walls are surrounded to form the assembly cavity; the annular main body at least partially protrudes out of the stator core to form a first boss; the end of the arc-shaped retaining wall protrudes out of the stator core to form a second boss; the second boss is flush with the first boss and overlaps the wire cover together.

[0012] The high-speed motor has an integrated structure of a housing and a stator, wherein the wire cover includes a main board body and a bending portion, the main board body is annular in shape, the inner diameter of the main board body is less than or equal to the diameter of the radial cross-section of the assembly cavity; the outer diameter of the main board body is equal to the outer diameter of the annular body; the bending portion is arranged at the outer edge of the main board body and is bent toward the annular body, surrounding and fitting the outer cylindrical surface of the first boss.

[0013] The high-speed motor has an integrated structure of a housing and a stator, wherein the outer diameter of the first boss is smaller than the outer diameter of the stator core, a connecting end surface is provided on one end of the stator core facing the wire cover, and the first boss is formed on the connecting end surface; and the plastic housing is integrally injection molded on the connecting end surface.

[0014] The housing and stator of the high-speed motor are integrally formed, wherein the wire cover is a metal wire cover or an alloy wire cover; and / or the bearing chamber insert is a metal insert or an alloy insert.

[0015] The present application also discloses a method for forming a housing and stator integrated structure of a high-speed motor as described above, which comprises:

[0016] An injection mold is provided; wherein the injection mold comprises a lower mold, an upper mold and a round core rod, the lower mold and the upper mold are adapted to form a molding cavity, and the round core rod is arranged in the molding cavity;

[0017] The bearing chamber insert, the wire protection cover and the stator component are sequentially sleeved on the round core rod, and the upper mold is covered on the lower mold to close the molding cavity;

[0018] Injecting plastic material into the molding cavity and cooling it to form a plastic shell;

[0019] Open the mold and take out the integrated structure of the high-speed motor housing and stator.

[0020] The molding method of the integrated molding structure of the housing and stator of the high-speed motor, wherein the round core rod comprises a lower round core segment and an upper round core segment connected in sequence, the shape of the lower round core segment is the same as the shape of the assembly chamber; the shape of the upper round core segment is the same as the shape of the assembly cavity; the diameter of the upper round core segment is smaller than the diameter of the lower round core segment;

[0021] The step of sequentially sleeve the bearing chamber insert, the wire protection cover and the stator component onto the round core rod specifically includes:

[0022] Sleeve the bearing chamber insert onto the lower circular core segment;

[0023] The wire protection cover and the stator component are coaxially assembled and then sleeved together on the upper circular core segment; the wire protection cover is in contact with the end of the lower circular core segment.

[0024] Compared with the prior art, the embodiments of the present invention have the following advantages:

[0025] The integrated molding structure of the housing and stator of the high-speed motor disclosed in the present invention wraps the stator component and the rotor of the high-speed motor in a plastic shell. Only the rotor rotates in the high-speed motor as a whole. The stator component, wire protection cover, bearing chamber insert, plastic shell, etc. are connected as a whole, and the structure is stable, which is conducive to extending the service life.

[0026] In the present invention, the plastic housing is injection molded, the stator component, the wire cover and the bearing chamber insert are first fixed in the mold, and then the plastic material is injected for integrated processing, which saves the assembly process, is conducive to improving the production efficiency of high-speed motors and reducing processing costs. Moreover, compared with the traditional glue bonding process, the product formed by mold integration has a better connection effect, a stable structure, and does not need to consider the uniformity of bonding, which improves the production yield.

[0027] In addition, in the present invention, the plastic shell is butted against the end surface of the stator component and does not surround the outer circumferential surface of the stator component, thus being more conducive to heat dissipation. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0029] Figure 1 It is a structural schematic diagram of the integrated structure of the housing and stator of the high-speed motor in the present invention;

[0030] Figure 2 for Figure 1 Axial cross-sectional view along AA` direction;

[0031] Figure 3 It is a structural explosion diagram of the integrated structure of the housing and stator of the high-speed motor of the present invention;

[0032] Figure 4 It is a structural schematic diagram of the stator structure in the present invention;

[0033] Figure 5 It is a structural explosion diagram of the stator structure in the present invention;

[0034] Figure 6 It is a structural schematic diagram of the high-speed motor in the present invention;

[0035] Figure 7 The present invention is a flow chart of a method for forming an integrated structure of a housing and a stator of a high-speed motor.

[0036] Among them, 10, stator component; 11, assembly cavity; 12, stator core; 121, winding teeth; 13, rubber-coated bracket; 131, annular body; 1311, first boss; 132, winding part; 133, arc-shaped retaining wall; 1331, second boss; 20, wire protection cover; 21, through hole; 22, main board; 23, bending part; 30, bearing chamber insert; 31, assembly chamber; 40, plastic shell; 41, inner ring connection part; 42, wind guide plate; 43, outer ring connection part; 50, rotor; 60, propeller. DETAILED DESCRIPTION

[0037] In order to enable those skilled in the art to better understand the scheme of the present invention, the technical scheme in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0038] See also Figure 1 , Figure 2 , Figure 3 and Figure 6 As shown, in one embodiment of the present invention application, a high-speed motor housing and stator integrated molding structure is disclosed, which includes a stator component 10, a wire protection cover 20, a bearing chamber insert 30 and a plastic shell 40, and a plurality of coils are arranged circumferentially on the stator component 10, and the plurality of coils are surrounded to form an assembly cavity 11, and the assembly cavity 11 extends along the length direction of the stator component 10. The wire protection cover 20 is covered on the end surface of the stator component 10 to cover the coil; a through hole 21 is formed on the wire protection cover 20 at the entrance position of the assembly cavity 11; the bearing chamber insert 30 is arranged on the side of the wire protection cover 20 away from the stator component 10; an assembly chamber 31 is arranged on the bearing chamber insert 30; the assembly chamber 31, the through hole 21 and the assembly cavity 11 are connected in sequence and coaxially arranged for assembling the rotor 50 of the high-speed motor; the plastic shell 40 is integrally injection molded on the end surface of the stator component 10, the outer circumferential surface of the wire protection cover 20 and the outer circumferential surface of the bearing chamber insert 30.

[0039] The integrated molding structure of the housing and stator of the high-speed motor disclosed in this embodiment wraps the stator component 10 and the rotor 50 of the high-speed motor in a plastic shell 40. Only the rotor 50 rotates in the high-speed motor as a whole. The stator component 10, the wire cover 20, the bearing chamber insert 30, the plastic shell 40, etc. are connected as a whole, and the structure is stable, which is conducive to extending the service life.

[0040] Specifically, in this embodiment, a plurality of coils are wound on the stator component 10, and the wire protection cover 20 is used to cover the end surface of the stator component 10. When the plastic housing 40 is formed, the injected high-temperature plastic material contacts and protects the wire protection cover 20. However, the plastic material is blocked by the wire protection cover 20 and does not contact the coils, thereby preventing the high temperature from damaging the coils in the stator component 10, protecting the structure of the stator component 10, and allowing the manufactured housing and stator integrated molding structure to work normally, thereby improving the production yield of the integrated molding process.

[0041] Specifically, the stator component 10, the wire protection cover 20 and the bearing chamber insert 30 disclosed in this embodiment can be pre-fixed by physical assembly methods such as welding and bonding, and then placed in an injection mold to form a plastic housing 40 by one-time injection molding.

[0042] In another implementation of the present embodiment, the stator component 10, the wire cover 20 and the bearing chamber insert 30 only need to be aligned in sequence and arranged coaxially so that the assembly chamber 31, the through hole 21 and the assembly cavity 11 extend in a straight line direction. No fixed connection is required in advance. During the integrated injection molding process, the plastic shell 40 is connected to the end of the stator component 10, to the outer cylindrical surface of the wire cover 20, and to the outer cylindrical surface of the bearing chamber insert 30, so that the various components are connected into one to form a complete and structurally stable integrated molding structure of the shell and stator, which can optimize the processing flow and help improve production efficiency.

[0043] Specifically, the rotor 50 of the high-speed motor generally includes a rotating shaft and a magnetic part. One end of the rotating shaft is arranged in the assembly chamber 31, and a bearing is sleeved to abut the side wall of the assembly chamber 31 to maintain stability; the other end of the rotating shaft is inserted into the assembly cavity 11 through the through hole 21, and a magnetic part, such as a magnetic steel or a magnet, is nested. When the coil is energized, a magnetic field is generated, driving the magnetic part to rotate, thereby driving the rotating shaft to rotate, completing the conversion of electrical energy into mechanical energy. In this embodiment, the bearing chamber insert 30 is provided to block the plastic material when manufacturing the plastic housing 40, and to reserve the assembly chamber 31 connected to the through hole 21 to facilitate the assembly of the bearing and the rotating shaft.

[0044] In this embodiment, the plastic housing 40 is formed by integrated injection molding. The stator component 10, the wire protection cover 20 and the bearing chamber insert 30 are first fixed in the mold, and then the plastic material is injected for integrated processing, which saves the assembly process, is conducive to improving the production efficiency of high-speed motors and reducing processing costs. Moreover, compared with the traditional glue bonding process, the product connection effect of the mold integrated molding is better, and there is no need to consider the uniformity of bonding, which improves the production yield.

[0045] In addition, in this embodiment, the plastic housing 40 is butted against the end surface of the stator component 10 and does not surround the outer circumferential surface of the stator component 10 , thus being more conducive to heat dissipation.

[0046] like Figure 2 and Figure 3 As shown, as an implementation of this embodiment, it is disclosed that the outer circumferential surface of the bearing chamber insert 30 is provided with tooth patterns. In this embodiment, the roughness of the outer circumferential surface of the bearing chamber insert 30 is increased by providing the tooth patterns, so that during the injection molding process, the connection effect between the plastic material and the outer circumferential surface of the bearing chamber insert 30 is better, which is conducive to molding and improving the stability of the structure.

[0047] Specifically, the outer circumferential surface of the bearing chamber insert 30 may be provided with teeth in an annular shape, and the shape of the teeth may be stripe, grid, matrix, etc. It should be noted that the shapes of the teeth are only exemplified in this embodiment, but the protection scope of the present invention is not limited thereto, and teeth of other shapes, as long as they can achieve the technical effects disclosed in this application, should also be within the protection scope of this application as an equivalent replacement of the concept of the present invention.

[0048] Specifically, as another implementation of this embodiment, the wire protection cover 20 is disclosed to be a metal wire protection cover or an alloy wire protection cover. Taking advantage of the high hardness, good supporting performance, and good heat resistance of metal and alloy structures, the structure can be kept stable during the injection molding process, supporting the plastic material and facilitating cooling and shaping.

[0049] Specifically, as another implementation of this embodiment, the bearing chamber insert 30 is disclosed as a metal insert or an alloy insert. For example, the bearing chamber insert 30 can be a copper metal insert or a copper-aluminum alloy insert. The bearing chamber insert 30 has high hardness and high stability, which is conducive to supporting the molding of the plastic housing 40 and supporting the rotor 50 of the high-speed motor inside, so that the structure of the high-speed motor is stable and the service life is long.

[0050] In this embodiment, the wire protection cover 20 and the bearing chamber insert 30 can be made of the same material to reduce the types of manufacturing materials and reduce production costs.

[0051] Specifically, the plastic housing 40 disclosed in this embodiment includes but is not limited to a housing made of plastic materials such as polyethylene, polypropylene, polyvinyl chloride, and polycarbonate, and the stator component 10 is made of a conventional stator core 12 wound with enameled wire. The metal part of the stator core 12 can be connected to the plastic housing 40 by nano injection molding technology, and the connection effect is good and the product structure is stable.

[0052] It should be noted that the types of plastic shells 40 are only exemplified in this embodiment, but the protection scope of the present invention is not limited thereto. As long as other types of plastic shells 40 can achieve the technical effects disclosed in this application, they should also be within the protection scope of this application as equivalent replacements for the concepts of the present invention.

[0053] like Figure 2As shown, as another implementation of this embodiment, the plastic shell 40 is disclosed to include an inner ring connecting portion 41, an outer ring connecting portion 43 and a plurality of air guide plates 42, wherein the inner ring connecting portion 41 is connected to the stator component 10, and is nested on the outer circumferential surface of the wire protection cover 20 and the outer circumferential surface of the bearing chamber insert 30; a plurality of air guide plates 42 are arranged in a ring shape on the outer side of the inner ring connecting portion 41; the outer ring connecting portion 43 is sleeved on the outer side of the inner ring connecting portion 41, and is connected to the air guide plates 42; two adjacent air guide plates 42 and the inner ring connecting portion 41 and the outer ring connecting portion 43 together constitute an air duct.

[0054] Since the high-speed motor disclosed in this embodiment has a high rotation speed, heat dissipation can be accelerated by setting a heat dissipation structure to avoid failure due to overheating during operation. Figure 6 As shown, a propeller 60 can be sleeved on the rotor 50 of the high-speed motor. When the propeller 60 rotates, air is blown along the axial direction of the high-speed motor, increasing the air flow on the outer wall of the high-speed motor, thereby achieving the effect of accelerating heat dissipation. A plurality of air guide plates 42 are arranged between the inner ring connection portion 41 and the outer ring connection portion 43 of the plastic shell 40. The specific number can be 5, 7, 9, etc., which can be selected according to the size of the high-speed motor. A plurality of air ducts are formed between the inner ring connection portion 41 and the outer ring connection portion 43, which play a guiding role and guide the air to quickly pass over the outer cylindrical surface of the inner ring connection portion 41 and the stator component 10. When the propeller 60 rotates, the air in the air duct is blown out, thereby taking away the heat on the surface of the inner ring connection portion 41 to improve the heat dissipation speed of the high-speed motor.

[0055] Specifically, in this embodiment, the inner ring connection part 41 mainly serves to connect the stator component 10, the wire cover 20 and the bearing chamber insert 30, and plays a protective role. At the same time, a plurality of air guide plates 42 are circumferentially arranged on the outer surface of the inner ring connection part 41, and the shape of the air guide plates 42 is spiral, so as to increase the length of the air duct and improve the heat dissipation efficiency. The outer ring connection part 43 surrounds a plurality of air guide plates 42, so that the side of the air duct is closed, leaving only the air inlet and the air outlet along the axial direction of the high-speed motor, further improving the orderliness of the air flow in the air duct. When the propeller 60 blows air at the air inlet, the air in the air duct is blown out from the air outlet, forming a negative pressure, which is conducive to rapid air intake, thereby increasing the air flow speed in the air duct.

[0056] Specifically, the inner ring connection part 41, the plurality of air guide plates 42, and the outer ring connection part 43 disclosed in the present embodiment are interconnected and integrally formed, which is convenient to manufacture and has stable connection, and is conducive to maintaining the stability of the air duct.

[0057] For example Figure 2As shown, as another implementation of this embodiment, it is disclosed that the outer circular surface of the inner ring connecting portion 41 is flush with the outer circular surface of the stator component 10; one end of the air guide plate 42 is arranged on the outer circular surface of the inner ring connecting portion 41, and the other end extends toward the stator component 10 and contacts with the outer circular surface of the stator component 10.

[0058] In this embodiment, the inner ring connection portion 41 is connected to the stator component 10 as a whole, the outer surface is flush, and the overall shape is cylindrical, so the air guide plate 42 extends from the inner ring connection portion 41 to the stator component 10 and fits the outer surface of the stator component 10. The air duct formed between adjacent air guide plates 42 is also composed of part of the stator component 10, so during the heat dissipation process, the stator component 10 can be directly cooled to improve the heat dissipation efficiency.

[0059] In a conventional high-speed motor, the stator structure is mounted in a housing. During the heat dissipation process, the heat needs to be conducted through the housing and then dissipated, which obviously has a slow heat dissipation speed. In this embodiment, the heat is directly taken away from the surface of the stator structure to dissipate the heat, thereby increasing the heat dissipation speed, which is beneficial to improving the performance of the high-speed motor and reducing the overheating problem.

[0060] Specifically, as another implementation of this embodiment, it is disclosed that the aperture of the via hole 21 is smaller than or equal to the diameter of the radial cross section of the assembly cavity 11 ; and the aperture of the via hole 21 is larger than the diameter of the radial cross section of the assembly chamber 31 .

[0061] In this embodiment, the diameter of the through hole 21 is set to be smaller than or equal to the diameter of the radial cross section of the assembly cavity 11, so as to ensure that the edge of the wire protection cover 20 extends to the inner side of the stator component 10, so that the wire protection cover 20 completely shields the coil and plays a protective role. The diameter of the through hole 21 is larger than the diameter of the radial cross section of the assembly chamber 31, so as to avoid glue leakage during the injection molding process and protect the stator component 10.

[0062] Specifically, the plastic shell 40 disclosed in this embodiment is molded on the outside of the stator component 10, the wire cover 20 and the bearing chamber insert 30. In order to improve the yield of product production, a core rod can be set in the mold before molding to insert the stator component 10, the wire cover 20 and the bearing chamber insert 30. Specifically, a core rod with the same shape as the rotor 50 of the high-speed motor is set, and before molding, the core rod is inserted into the assembly chamber 31, the through hole 21 and the assembly cavity 11. The stator component 10, the wire cover 20 and the bearing chamber insert 30 are arranged coaxially and kept in axial contact with each other to maintain a stable state, and then the injection molding process is performed.

[0063] like Figure 3As shown, as another implementation of this embodiment, the wire protection cover 20 is disclosed to include a main board body 22 and a bending portion 23, the main board body 22 is annular in shape, the inner diameter of the main board body 22 is less than or equal to the diameter of the radial cross-section of the assembly cavity 11; the outer diameter of the main board body 22 is equal to the outer diameter of the annular body 131; the bending portion 23 is arranged at the outer edge of the main board body 22, and is bent toward the annular body 131, surrounding and fitting the outer circular surface of the first boss 1311.

[0064] In this embodiment, the inner side of the main board body 22 contacts the second boss 1331, and the outer side contacts the first boss 1311, maintaining stability, and covering the coil through the main board body 22; the outer cylindrical surface of the first boss 1311 is surrounded by the bending portion 23, so that the wire protection cover 20 is completely covered on the stator component 10, and the bending portion 23 is constrained by the first boss 1311 to prevent the wire protection cover 20 from shifting or slipping, thereby further improving the stability of the assembly of the wire protection cover 20 and the stator component 10.

[0065] For example Figure 2 As shown, as another implementation of this embodiment, it is disclosed that the outer diameter of the first boss 1311 is smaller than the outer diameter of the stator core 12, and a connecting end surface is provided on the end of the stator core 12 facing the wire cover 20, and the first boss 1311 is formed on the connecting end surface; the plastic shell 40 is integrally injection molded on the connecting end surface.

[0066] The annular body 131 disclosed in this embodiment is attached to the inner circumferential surface of the stator core 12, and the first boss 1311 protrudes from the stator core 12 and is partially wrapped on the end surface of the stator core 12, thereby maintaining the relative stability of the rubber-coated bracket 13 and the stator core 12. The connecting end surface is located outside the first boss 1311, and the plastic shell 40 is in contact with the connecting end surface. Through the injection molding process, the stator component 10 and the plastic shell 40 are connected, and the connection gap is small and the connection is tight.

[0067] like Figure 4 and Figure 5 As shown, as another implementation of this embodiment, it is disclosed that the stator component 10 includes a stator core 12 and a rubber-coated bracket 13, the stator core 12 is annular in shape, and a plurality of winding teeth 121 are protruding from the inner circumferential surface of the stator core 12; the rubber-coated bracket 13 is nested on the stator core 12; the rubber-coated bracket 13 includes an annular main body 131 arranged to fit the inner circumferential surface of the stator core 12, a winding portion 132 connected to the annular main body 131 and wrapping the winding teeth 121, and an arc-shaped retaining wall 133 connected to the winding portion 132.

[0068] In this embodiment, the winding part 132 is used to wind the enameled wire to form the coil, and the annular body 131 separates the coil from the stator core 12 to avoid circuit failure. In addition, the coil is formed by winding the enameled wire multiple times and has a certain thickness. The annular body 131 and the arc-shaped retaining wall 133 are arranged on both sides of the coil to play a limiting role and prevent the coil from loosening.

[0069] Specifically, the rubber-coated bracket 13 disclosed in this embodiment is a plastic bracket, which has good insulation and is easy to manufacture. The annular body 131, the winding portion 132 and the arc-shaped retaining wall 133 can be integrally formed, with a fast production speed, and the product is light in weight and has a long service life, which is conducive to improving the performance of high-speed motors and extending their service life.

[0070] like Figure 4 As shown, the arc-shaped retaining wall 133 is arranged on one end of the winding part 132 away from the annular main body 131, and a plurality of the arc-shaped retaining walls 133 together form the assembly cavity 11; the annular main body 131 at least partially protrudes out of the stator core 12 to form a first boss 1311; the end of the arc-shaped retaining wall 133 protrudes out of the stator core 12 to form a second boss 1331; the second boss 1331 is flush with the first boss 1311, and together overlap the wire protection cover 20.

[0071] In this embodiment, the first boss 1311 and the second boss 1331 extend outside the stator core 12 to facilitate positioning and assembly of the wire protection cover 20, so that the wire protection cover 20 is accurately covered on the first boss 1311 and the second boss 1331, and the coil between the first boss 1311 and the second boss 1331 is completely covered to form protection. At the same time, the first boss 1311 and the second boss 1331 support the wire protection cover 20 inside and outside, so that the wire protection cover 20 is stable, so that the bearing chamber insert 30 is assembled on the wire protection cover 20, and it remains stable during the process of integrated injection molding of the plastic housing 40.

[0072] like Figure 7 As shown, as another embodiment of the present application, a molding method for an integrated molding structure of a housing and a stator of a high-speed motor as described above is disclosed, which includes:

[0073] S100, providing an injection mold; wherein the injection mold comprises a lower mold, an upper mold and a round core rod, the lower mold and the upper mold are adapted to form a molding cavity, and the round core rod is arranged in the molding cavity.

[0074] In this embodiment, the injection mold is a split mold, that is, the mold is designed to be two opposite halves, which are the lower mold and the upper mold when assembled up and down, and the left and right half molds when assembled left and right. The mold is divided into two halves to facilitate the demoulding and demoulding of the integrated molding structure of the housing and the stator. The round mandrel is manufactured in the shape of the rotor 50 of the high-speed motor, and is detachably connected to the lower mold, and is used to sleeve the bearing chamber insert 30, the wire cover 20 and the stator component 10.

[0075] In addition, in one implementation of the present embodiment, the lower mold and the round core rod are integrally formed to reduce the assembly gap and make the injection molding more precise. In another implementation of the present embodiment, the round core rod can also be manufactured separately and then fixed to the lower mold by welding or plugging. Before injection molding, the round core rod is assembled with the lower mold, and the round core rod is vertically arranged in the mold cavity of the lower mold with the top facing the upper mold. After the bearing chamber insert 30, the wire cover 20 and the stator component 10 are sleeved, the upper mold can be closed to contact the round core rod to achieve fixation of both ends of the round core rod, thereby maintaining stability during the injection molding process.

[0076] S200, the bearing chamber insert 30, the wire protection cover 20 and the stator component 10 are sequentially mounted on the round core rod, and the upper mold is covered on the lower mold to close the molding cavity.

[0077] The bearing chamber insert 30, the wire protection cover 20 and the stator component 10 are sequentially mounted on the round core rod so that the three are coaxially arranged and maintain a high concentricity. Then, the upper mold is covered to close the molding cavity to facilitate the injection of plastic material, and the plastic shell 40 is integrally molded on the stator component 10, the wire protection cover 20 and the bearing chamber insert 30.

[0078] S300 , injecting plastic material into the molding cavity and cooling the mold to form a plastic housing 40 .

[0079] Liquid plastic material is injected into the molding cavity to fill the molding cavity, and then cooled and shaped in a natural environment to obtain the plastic housing 40 . The processing efficiency is high and the operation is simple.

[0080] S400, open the mold and take out the integrated structure of the housing and stator of the high-speed motor.

[0081] Finally, the upper mold and the lower mold are separated, and the round core rod is taken out, and the integrated molding structure of the shell and the stator is demoulded to complete the molding process.

[0082] It can be seen that the molding method disclosed in this embodiment is simple to operate. First, the plastic shell 40 is molded in one go to achieve the connection between the plastic shell 40 and the stator component 10, the wire cover 20 and the bearing chamber insert 30, which simplifies the processing flow and is conducive to improving the processing efficiency; second, the connection is completed during the injection molding process, replacing the traditional bonding process, and the plastic shell 40 is tightly connected with the stator component 10, the wire cover 20 and the bearing chamber insert 30, with high assembly accuracy, good integration effect, not easy to disassemble, and long service life; third, the positioning and locating processes of the stator component 10, the wire cover 20, the bearing chamber insert 30, the plastic shell 40 and other structures are omitted, and the concentricity of the stator component 10, the wire cover 20 and the bearing chamber insert 30 is high, which is conducive to improving the product qualification rate.

[0083] Specifically, as another implementation of this embodiment, it is disclosed that the round core rod includes a lower round core segment and an upper round core segment connected in sequence, the shape of the lower round core segment is the same as the shape of the assembly chamber 31; the shape of the upper round core segment is the same as the shape of the assembly cavity 11; the diameter of the upper round core segment is smaller than the diameter of the lower round core segment; the step of sequentially sleeve the bearing chamber insert 30, the wire protection cover 20 and the stator component 10 on the round core rod specifically includes:

[0084] M100, sleeve the bearing chamber insert 30 onto the lower circular core segment;

[0085] M200, the wire protection cover 20 and the stator component 10 are coaxially assembled and then sleeved together on the upper circular core segment; the wire protection cover 20 is in contact with the end of the lower circular core segment.

[0086] In this embodiment, since the plastic housing 40 is integrally formed, high processing precision is required during the injection molding process. The stator component 10, the wire cover 20 and the bearing chamber insert 30 are all arranged in the mold. If the processed product is unqualified, the loss cost is very high.

[0087] Therefore, in this embodiment, a two-section round core rod is provided to correspond to the bearing chamber insert 30 and the stator component 10, so that the bearing chamber, the wire cover 20, and the stator component 10 can only be assembled in sequence, which is beneficial to improving the orderliness of the molding process; and the lower round core segment and the upper round core segment are manufactured according to the shape of the assembly chamber 31 and the assembly cavity 11, and the assembly stability is high. During the injection molding process, the bearing chamber insert 30, the wire cover 20, the stator structure, etc. remain stable, which is beneficial to improving the product yield, reducing the product unqualified rate, and reducing the production cost.

[0088] It should be understood that the various parts of the present application can be implemented in hardware, software, firmware or a combination thereof. In the above-mentioned embodiments, multiple steps or methods can be implemented in software or firmware stored in a memory and executed by a suitable instruction execution system. If implemented in hardware, as in another embodiment, it can be implemented by any one of the following technologies known in the art or their combination: a discrete logic circuit having a logic gate circuit for implementing a logic function on a data signal, a dedicated integrated circuit having a suitable combination of logic gate circuits, a programmable gate array, a field programmable gate array, etc.

[0089] In addition, each functional unit in each embodiment of the present application may be integrated into a processing module, or each unit may exist physically separately, or two or more units may be integrated into one module. The above-mentioned integrated module may be implemented in the form of hardware or in the form of a software functional module. If the integrated module is implemented in the form of a software functional module and sold or used as an independent product, it may also be stored in a computer-readable storage medium.

[0090] In summary, the present application discloses a high-speed motor housing and stator integrated molding structure, which includes a stator component 10, a wire protection cover 20, a bearing chamber insert 30 and a plastic shell 40, wherein the stator component 10 is circumferentially arranged with a plurality of coils, and the plurality of coils are surrounded to form an assembly cavity 11, and the assembly cavity 11 extends along the length direction of the stator component 10; the wire protection cover 20 is covered on the end surface of the stator component 10 to cover the coil; the wire protection cover 20 is directly opposite to the assembly cavity 11; A through hole 21 is formed at the entrance of the cavity 11; the bearing chamber insert 30 is arranged on the side of the wire cover 20 away from the stator component 10; the bearing chamber insert 30 is provided with an assembly chamber 31; the assembly chamber 31, the through hole 21 and the assembly cavity 11 are sequentially connected and coaxially arranged for assembling the rotor 50 of the high-speed motor; the plastic shell 40 is integrally injection molded on the end face of the stator component 10, the outer circumferential surface of the wire cover 20 and the outer circumferential surface of the bearing chamber insert 30. In this embodiment, the plastic shell 40 is integrally injection molded, and the stator component 10, the wire cover 20 and the bearing chamber insert 30 are first fixed in the mold, and then integrally processed by injecting plastic material, which saves the assembly process, is conducive to improving the production efficiency of the high-speed motor and reducing the processing cost. Moreover, compared with the traditional glue bonding process, the product formed by the mold integration has a better connection effect, and there is no need to consider the uniformity of bonding, which improves the production yield.

[0091] It should be noted that, in the absence of conflict, the embodiments and features in the embodiments of the present application may be combined with each other.

[0092] It should be noted that the present invention takes the integrated molding structure of the casing and stator of a high-speed motor and its molding method as an example to introduce the specific structure and working principle of the present invention, but the application of the present invention is not limited to the integrated molding structure of the casing and stator of a high-speed motor and its molding method, and can also be applied to the production and use of other similar workpieces.

[0093] It should be understood that the present invention is not limited to the exact construction that has been described above and shown in the drawings and that various modifications and changes may be made without departing from the scope thereof. The scope of the present invention is limited only by the appended claims.

[0094] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. A high-speed motor housing and stator integrated molding structure, characterized in that: include: A stator component, wherein a plurality of coils are arranged circumferentially on the stator component, and the plurality of coils are surrounded to form an assembly cavity, and the assembly cavity extends along the length direction of the stator component; A wire protection cover, which is covered on the end surface of the stator component and is used to cover the coil; A through hole is formed on the wire protection cover at a position facing the entrance of the assembly cavity; A bearing chamber insert is arranged on the side of the wire protection cover away from the stator component; an assembly chamber is arranged on the bearing chamber insert; the assembly chamber, the through hole and the assembly cavity are sequentially connected and coaxially arranged for assembling the rotor of the high-speed motor; The plastic shell is integrally injection-molded on the end surface of the stator component, the outer circumferential surface of the wire protection cover and the outer circumferential surface of the bearing chamber insert.

2. The integrated structure of the housing and stator of the high-speed motor according to claim 1 is characterized in that: The plastic housing comprises: An inner ring connecting portion is connected to the stator component and is nested on the outer circumferential surface of the wire protection cover and the outer circumferential surface of the bearing chamber insert; A plurality of wind deflectors are arranged in a ring shape on the outer side of the inner ring connecting portion; An outer ring connecting portion is sleeved on the outer side of the inner ring connecting portion and connected to the air guide plate; The two adjacent air guide plates, the inner ring connecting portion and the outer ring connecting portion together form an air duct.

3. The integrated structure of the housing and stator of the high-speed motor according to claim 2, characterized in that: The outer circumferential surface of the inner ring connecting portion is flush with the outer circumferential surface of the stator component; one end of the air guide plate is arranged on the outer circumferential surface of the inner ring connecting portion, and the other end extends toward the stator component and contacts the outer circumferential surface of the stator component.

4. The integrated structure of the housing and stator of the high-speed motor according to claim 1, characterized in that: The aperture of the via hole is smaller than or equal to the diameter of the radial cross section of the assembly cavity; and the aperture of the via hole is larger than the diameter of the radial cross section of the assembly chamber.

5. The integrated structure of the housing and stator of the high-speed motor according to claim 1, characterized in that: The stator component comprises: A stator core, wherein the stator core is annular in shape, and a plurality of winding teeth are protruded and formed on the inner circumferential surface of the stator core; A rubber-coated bracket is nested on the stator core; the rubber-coated bracket comprises an annular body arranged to fit the inner circumference of the stator core, a winding portion connected to the annular body and wrapping the winding teeth, and an arc-shaped retaining wall connected to the winding portion; the winding portion is used to wind the enameled wire to form the coil, the arc-shaped retaining wall is arranged on one end of the winding portion away from the annular body, and a plurality of the arc-shaped retaining walls surround the assembly cavity; Wherein, the annular body at least partially protrudes out of the stator core to form a first boss; the end of the arc-shaped retaining wall protrudes out of the stator core to form a second boss; the second boss is flush with the first boss and overlaps the wire cover together.

6. The integrated structure of the housing and stator of the high-speed motor according to claim 5, characterized in that: The wire protection cover comprises: A main board body, wherein the main board body is annular in shape, the inner diameter of the main board body is less than or equal to the diameter of the radial cross section of the assembly cavity; and the outer diameter of the main board body is equal to the outer diameter of the annular body; The bending portion is arranged at the outer edge of the main body and is bent toward the annular body to surround and fit the outer circumferential surface of the first boss.

7. The integrated structure of the housing and stator of the high-speed motor according to claim 5, characterized in that: The outer diameter of the first boss is smaller than the outer diameter of the stator core, and a connecting end surface is provided on one end of the stator core facing the wire protection cover, and the first boss is formed on the connecting end surface; Wherein, the plastic shell is integrally injection-molded on the connecting end surface.

8. The integrated structure of the housing and stator of a high-speed motor according to any one of claims 1 to 7, characterized in that: The wire protection cover is a metal wire protection cover or an alloy wire protection cover; and / or the bearing chamber insert is a metal insert or an alloy insert.

9. A method for forming the integrated structure of the housing and stator of a high-speed motor as claimed in any one of claims 1 to 8, characterized in that: include: An injection mold is provided; wherein the injection mold comprises a lower mold, an upper mold and a round core rod, the lower mold and the upper mold are adapted to form a molding cavity, and the round core rod is arranged in the molding cavity; The bearing chamber insert, the wire protection cover and the stator component are sequentially sleeved on the round core rod, and the upper mold is covered on the lower mold to close the molding cavity; Injecting plastic material into the molding cavity and cooling it to form a plastic shell; Open the mold and take out the integrated structure of the high-speed motor housing and stator.

10. The method for forming the integrated structure of the housing and stator of a high-speed motor according to claim 9, characterized in that: The round core rod comprises a lower round core segment and an upper round core segment connected in sequence, the shape of the lower round core segment is the same as the shape of the assembly chamber; the shape of the upper round core segment is the same as the shape of the assembly cavity; the diameter of the upper round core segment is smaller than the diameter of the lower round core segment; The step of sequentially sleeve the bearing chamber insert, the wire protection cover and the stator component onto the round core rod specifically includes: Sleeve the bearing chamber insert onto the lower circular core segment; The wire protection cover and the stator component are coaxially assembled and then sleeved together on the upper circular core segment; wherein the wire protection cover is in contact with the end of the lower circular core segment.

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