Stator for electric motor without varnish drip
By adopting the structure of the main body, the first plate, the second plate, the multiple conductors and the insulating layer in the stator of the electric motor, the relative movement between the conductor and the stator is suppressed, and the problem of difficulty in filling the gap of the varnish is solved, and corrosion resistance and pollution resistance are improved.
Patent Information
- Application Number
- CN202411463524.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2023-10-25
- Filing Date
- 2024-10-18
- Publication Date
- 2025-04-25
AI Technical Summary
During the production process of electric motors, it is difficult for varnish to fill the gap between the stator and the insulating paper and between the insulating paper and the conductive wire, resulting in insufficient corrosion resistance and pollution resistance.
A stator for an electric motor is designed, and a structure of a main body, a first plate, a second plate, a plurality of wires and an insulating layer is used to suppress relative movement between a single wire in the plurality of wires and the main body of the stator through the first plate and the second plate.
It effectively solves the problem that varnish is difficult to fill gaps, improves the corrosion resistance and pollution resistance of the electric motor, and extends its operating life.
Smart Images
Figure CN119891614A_ABST
Abstract
Description
Technical Field
[0001] The present disclosure relates to stators for electric motors. More particularly, the present disclosure relates to eliminating varnish dripping during the production of stators. Background Art
[0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
[0003] Electric propulsion devices in vehicles provide an alternative to internal combustion engines. Electric propulsion devices use electric motors to propel the vehicle. Applying varnish to such motors provides corrosion resistance and contamination resistance to the motors, thereby increasing the operating life of the electric propulsion device. The varnish can be applied with a machine designed to apply the varnish to various parts of the motor. However, in some cases, the varnish does not fill the gaps between the stator and the insulating paper of the electric motor and between the insulating paper and the conductive wires extending through the stator.
[0004] The present disclosure addresses challenges associated with applying varnish to electric motors. Summary of the invention
[0005] This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features.
[0006] In one form of the present disclosure, a stator for an electric motor includes: a body having a first end and a second end; a first plate mounted to the first end of the body; a second plate mounted to the second end of the body; and a plurality of wires and an insulating layer extending through the first plate, the body of the stator, and the second plate. The first plate and the second plate inhibit relative movement between individual wires of the plurality of wires and the body of the stator.
[0007] In a variation of the stator that can be implemented individually or in any combination, the first plate and the second plate are made of a plastic material; the plastic material is polyamideimide, polyphenylene sulfide or polyphenylene ether; the first plate and the second plate are made of a ceramic material; the first plate and the second plate are molded as a single integrated part; the first plate and the second plate are formed by two separate molded parts; the multiple wires include copper material; and bending of the multiple wires applies force to the first plate and the second plate to inhibit relative movement between the stator and a separate wire among the multiple wires.
[0008] In another form, a stator for an electric motor includes: a body having a plurality of slots; a plurality of wires and an insulation layer extending through the body; and at least one insert extending from an outer diameter to an inner diameter of the slots of the body and passing through at least a portion of the plurality of wires. The at least one insert inhibits relative movement between individual wires of the plurality of wires.
[0009] In a variation of this form that may be implemented individually or in any combination, at least one insert comprises a T-shaped portion and a wedge-shaped portion; the T-shaped portion comprises a longitudinal section; the longitudinal section is tapered; at least one insert is made of a plastic material; the plastic material is polyamideimide, polyphenylene sulfide or polyphenylene ether; at least one insert is made of a ceramic material; and at least one insert comprises a plurality of spaced-apart inserts.
[0010] In yet another form, a stator for an electric motor includes: a body having a plurality of slots; a plurality of wires and an insulating layer extending through the body; at least one insert extending from an outer diameter to an inner diameter of the slots of the body and passing through at least a portion of the plurality of wires; at least one other insert extending from an inner diameter of the slots of the body to a midpoint between the outer diameter and the inner diameter and passing through a sub-portion of the plurality of wires. The at least one insert and the at least one other insert inhibit relative movement between individual wires of the plurality of wires.
[0011] In a variation of the method that may be implemented alone or in any combination, each of the at least one insert and the at least another insert includes a T-shaped elongated portion and a wedge-shaped portion; the T-shaped elongated portion includes a tapered section; and the stator further includes a mechanism that locks the at least one insert and the another insert together at a midpoint to inhibit movement between individual wires of the plurality of wires.
[0012] Further areas of applicability will become apparent from the description provided herein.It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS
[0013] In order that the present disclosure may be better understood, various forms of the present disclosure will now be described by way of example with reference to the accompanying drawings, in which:
[0014] Figure 1 is a perspective view of a stator of an electric motor according to the principles of the present disclosure;
[0015] Figure 2 A stator having two annular disks according to the principles of the present disclosure is shown;
[0016] Figure 3A shows a portion of an annular disk formed from two separate layers in accordance with the principles of the present disclosure;
[0017] Figure 3B The present disclosure shows that when two layers are combined Figure 3A The portion of the annular disk shown;
[0018] Figure 4A According to the principles of the present disclosure, Figure 3B A cross-sectional view of the annular disk as seen along line 4A-4A;
[0019] Figure 4B According to the principles of the present disclosure Figure 4A A cross-sectional view of the annular disk in plane 4B-4B;
[0020] Figure 4C According to the principles of the present disclosure Figure 4A A cross-sectional view of the annular disk in plane 4C-4C;
[0021] Figure 5A shows a portion of another annular disk formed from two separate layers in accordance with the principles of the present disclosure;
[0022] Figure 5B The present disclosure shows that when two layers are combined Figure 5A The portion of the annular disk shown;
[0023] Fig. 6A According to the principles of the present disclosure, Figure 5B A cross-sectional view of the annular disk as seen along line 6A-6A;
[0024] Figure 6B According to the principles of the present disclosure Fig. 6A A cross-sectional view of the annular disk along plane 6B-6B;
[0025] Figure 6C According to the principles of the present disclosure Fig. 6A A cross-sectional view of the annular disk in plane 6C-6C;
[0026] Figure 7 An annular disk for inhibiting relative movement of individual wires in a stator according to the principles of the present disclosure is shown;
[0027] Fig. 8A is a perspective view of a wedge for inhibiting relative movement of individual conductors in a stator in accordance with the principles of the present disclosure;
[0028] Figure 8B According to the principles of the present disclosure, Fig. 8A a cross-sectional view of the wedge as viewed along line 8B-8B;
[0029] Figure 8C According to the principles of the present disclosure, Fig. 8A a cross-sectional view of the wedge as viewed along line 8C-8C;
[0030] Fig.8D According to the principles of the present disclosure, Fig. 8A a cross-sectional view of the wedge as viewed along line 8D-8D;
[0031] Fig. 9A shows a wedge positioned in place among a plurality of conductors of a stator in accordance with the principles of the present disclosure; and
[0032] Fig. 9B Two wedges are shown positioned in place among a plurality of wires of a stator in accordance with the principles of the present disclosure.
[0033] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. DETAILED DESCRIPTION
[0034] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate the same or corresponding parts and features.
[0035] refer to Figure 1 and Figure 2 , the electric motor 10 includes a stator 12 and a plurality of wires 14. The electric motor 10 is a component of an electric propulsion device for a motor vehicle (i.e., an "electric vehicle"). The electric motor 10 propels the motor vehicle by rotating one or more wheels of the motor vehicle. In one example, the electric motor 10 is the sole propulsion device of the vehicle, such as in a pure electric vehicle. Alternatively, the electric motor 10 may be part of a hybrid propulsion device including an internal combustion engine, such as in a hybrid electric vehicle.
[0036] The electric motor 10 includes a stator 12. The stator 12 is a fixed component of the electric motor 10 that provides a magnetic field through which the rotor rotates. The stator 12 keeps the magnetic field aligned to rotate the rotor. The stator 12 includes a plurality of laminations 18, i.e., sheets of material fused together. Each lamination 18 is an annular sheet of metal having a continuous outer edge 20 defining an outer diameter and a plurality of fingers 22 extending toward a center point of the annular sheet. The distal ends 24 of the fingers 22 define an inner diameter of the lamination 18. Each pair of adjacent fingers 22 of one of the laminations 18 defines a slot 26 therebetween. The slot 26 extends radially from the inner diameter to the middle diameter. The laminations 18 are fused at the outer diameter, such as by a weld, and the laminations 18 are free at the middle diameter and the inner diameter. The stator 12 includes a first lamination 40 at a first end 42 of the stator 12 and a last lamination at a second end 44. The laminations 18 have outer surfaces 48 that contact the outer surfaces of adjacent laminations 18.
[0037] The wires 14 are conductive materials, such as copper. The wires 14 provide power to generate a magnetic field that drives the rotor. The wires 14 are disposed in slots 26 and extend along the stator 12. The wires 14 are disposed in slots 26 defined by the fingers 22 of the laminations 18 from the middle diameter to the inner diameter.
[0038] A plate such as an annular disk 46 is provided at the first end 42 and the second end 44. The annular disk 46 is bolted to the stator 12 with a set of nuts 50 and a set of rods 52. The annular disk 46 is mirrored along the center plane 48 of the stator 12. Figure 4B and Figure 6B As shown, an insulating layer 60 is positioned in each slot 26 and between the wire 14 and the stator 12. The insulating layer 60 reduces or inhibits electrical conduction between the wire 14 and the stator 12. The insulating layer 60 is, for example, an electrically insulating paper layer. Each of the annular disks is formed of a ceramic or plastic material. For example, but not limited to, the plastic material may be polyamideimide, polyphenylene sulfide, or polyphenylene sulfide.
[0039] In one form, a portion of the annular disk 46 is Figure 3A and Figure 3B Annular disk 46a is shown as 46a in FIG. Portions of annular disk 46a surround a single slot 26 of stator 12 and are formed of two layers 54 and 56. Layer 54 is disposed adjacent stator 12, and layer 56 includes a set of slots 58 defined by a set of plates 59 that guide portions of a plurality of wires through layer 54 into stator 12. In some forms, layer 54 may be formed of paper. Slots 58 separate the plurality of wires 14 and inhibit relative movement between the wires 14. Annular disk 46a may be formed as a single integrated piece rather than being formed of two separate layers.
[0040] Further references Figure 4A , showing the annular disk 46a along Figure 3B A cross-sectional view of the annular disk as viewed along line 4A-4A, wherein the annular disk is attached to the stator 12. Figure 4B A cross-sectional view along plane 4B-4B of inner layer 54 is shown, and Figure 4C A cross-sectional view along plane 4C-4C of outer layer 56 is shown. Inner layer 54 of annular disk 46a provides space for insulating layer 60 and multiple wires 14, while outer layer 56 provides space only for multiple wires 14. Each of the multiple wires 14 is sandwiched between plates 59 that define slots 58 and are separated from other copper wires to inhibit movement between wires 14. Figure 2 and Figure 4B As shown, the plurality of wires 14 and the insulation layer 60 extend through the annular disk 46 at the first end 42 of the stator 12 , the body of the stator 12 , and the annular disk 46 at the second end 44 of the stator 12 .
[0041] In another form, a portion of the annular disk 46 is Figure 5A and Figure 5B 46b. Again, a portion of the annular disk 46b surrounds a single slot 26 of the stator 12 and is formed of two layers 61 and 62. Layer 61 is disposed adjacent to the stator 12, and layer 62 includes a set of slots 64 defined by a set of plates 65 that guide portions of the plurality of wires into the stator 12. In some forms, layer 61 may be formed of paper. The slots 64 separate the plurality of wires 14 and inhibit relative movement between the wires 14. The annular disk 46b may be formed as a single integrated piece, rather than being formed of two separate layers.
[0042] Further references Fig. 6A , showing the annular disk 46b along Figure 5B A cross-sectional view of the annular disk as viewed along line 6A-6A, wherein the annular disk is attached to the stator 12. Figure 6B A cross-sectional view along plane 6B-6B of inner layer 61 is shown, and Figure 6C A cross-sectional view along plane 6C-6C of outer layer 62 is shown. Inner layer 61 of annular disk 46b provides space for insulating layer 60 and multiple wires 14, while outer layer 62 provides space only for multiple wires 14. Each of the multiple wires 14 is sandwiched between plates 65 that define slots 64 and are separated from other copper wires to inhibit movement between wires 14. Figure 2 and Figure 6B As shown, the plurality of wires 14 and the insulation layer 60 extend through the annular disk 46 at the first end 42 of the stator 12 , the body of the stator 12 , and the annular disk 46 at the second end 44 of the stator 12 .
[0043] Thus, the present disclosure describes the use of an annular disk 46a or 46b that is structurally integrated into the stator 12 and the plurality of conductors 14 as a rigid single piece, such as Figure 7 As shown. Relative movement between individual wires in the plurality of wires 14 and between the stator 12 and the plurality of wires 14 is not allowed. The stator 12 is provided with a plurality of wires 14. The stator 12 is provided with a plurality of wires 14. The stator 12 is provided with a plurality of wires 14. The stator 12 is provided with a plurality of wires 14. Figure 2 ). The bending of the plurality of wires 14 near the inner diameter of the stator 12 and the annular disk 46a or 46b generates a force 62 that pushes against the outer layer 56 or 62 to hold the plurality of wires 14 against the stator 12. The plates 59 or 65 inside the outer layer 56 or 62 of the annular disk 46a or 46b hold each individual wire of the plurality of wires 14 to inhibit movement of the individual wires relative to the stator 12.
[0044] Now turn to FIG. 8A to FIG. 8D, shows an insert 100 that inhibits relative movement between the wires in the plurality of wires 14. The insert 100 includes a flat T-shaped portion 102 made of a longitudinal section 104 and a top section 106. A wedge-shaped portion 108 is attached to the longitudinal section 104. Figure 8B As shown, the elongated section 104 is tapered. Thus, the taper of the elongated section 104 and the shape of the wedge-shaped portion 108 enable the insert 100 to be placed through a plurality of conductors 14.
[0045] In one arrangement, Fig. 9A As shown, the insert 100 is placed through a portion of the plurality of wires 14. That is, the insert 100 extends from the outer diameter to the inner diameter of the corresponding slot 26 of the body of the stator 12 and extends through a sub-portion of the plurality of wires 14 to inhibit relative movement between individual wires in the plurality of wires 14. In various arrangements, multiple inserts 100 may be utilized.
[0046] In another arrangement, such as Fig. 9B As shown, a pair of inserts 106a and 106b are utilized. One insert 106a extends from the outer diameter of the slot 26 of the body of the stator 12 to the midpoint between the outer diameter and the inner diameter and passes through a sub-portion of the plurality of wires 14, and the other insert 106b extends from the inner diameter of the slot 26 of the body of the stator 12 to the midpoint between the outer diameter and the inner diameter and passes through a sub-portion of the plurality of wires 14. A mechanism locks the two inserts 106a and 106b together at the midpoint to inhibit movement between individual wires in the plurality of wires 14. In various arrangements, multiple pairs of inserts 106a and 106b 100 may be utilized.
[0047] In various arrangements, FIG. 8A to FIG. 8D , Fig. 9A and Fig. 9B The insert shown in is made of ceramic or plastic material. The plastic material can be polyamide-imide, polyphenylene sulfide or polyphenylene sulfide.
[0048] Among other advantages and benefits, the present disclosure describes assemblies that eliminate varnish dripping in electric motor production. Thus, these assemblies reduce the process complexity associated with the production of electric motors.
[0049] Unless otherwise expressly indicated herein, all numerical values indicating mechanical / thermal properties, composition percentages, dimensions and / or tolerances or other characteristics when describing the scope of the present disclosure should be understood to be modified by the word "about" or "approximately". Such modifications are desirable for a variety of reasons, including: industrial practice; material, manufacturing and assembly tolerances; and testing capabilities.
[0050] As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A or B or C), using a non-exclusive logical "or", and should not be construed to mean "at least one of A, at least one of B, and at least one of C."
[0051] The description of the present disclosure is merely exemplary in nature, and thus, variations that do not depart from the essence of the present disclosure are intended to be within the scope of the present disclosure. Such variations should not be regarded as a departure from the spirit and scope of the present disclosure.
[0052] According to the present invention, there is provided a stator for an electric motor, the stator having: a body having a first end and a second end; a first plate mounted to the first end of the body; a second plate mounted to the second end of the body; and a plurality of wires and an insulating layer extending through the first plate, the body of the stator, and the second plate, wherein the first plate and the second plate inhibit relative movement between individual wires of the plurality of wires and the body of the stator.
[0053] According to one embodiment, the first plate and the second plate are made of plastic material.
[0054] According to one embodiment, the plastic material is polyamideimide, polyphenylene sulfide or polyphenylene oxide.
[0055] According to one embodiment, the first plate and the second plate are made of a ceramic material.
[0056] According to one embodiment, the first plate and the second plate are formed as a single integrated piece.
[0057] According to one embodiment, the first plate and the second plate are formed from two separate profiled parts.
[0058] According to one embodiment, the plurality of conductive wires include a copper material.
[0059] According to one embodiment, bending of the plurality of wires applies a force to the first plate and the second plate to inhibit relative movement between the stator and individual wires of the plurality of wires.
[0060] According to the present invention, a stator for an electric motor is provided, the stator having: a body having a plurality of slots; a plurality of wires and an insulating layer extending through the body; at least one insert extending from an outer diameter to an inner diameter of the slots of the body and passing through at least a portion of the plurality of wires; at least one other insert extending from an inner diameter to a midpoint between the outer diameter and the inner diameter of the slots of the body and passing through a sub-portion of the plurality of wires, wherein the at least one insert and the at least one other insert inhibit relative movement between individual wires of the plurality of wires.
[0061] According to one embodiment, each of the at least one insert and the at least one other insert comprises a T-shaped elongated portion and a wedge-shaped portion.
[0062] According to one embodiment, the T-shaped elongated portion comprises a tapered section.
[0063] According to one embodiment, the invention also features a mechanism that locks at least one insert and another insert together at a midpoint to inhibit movement between individual wires of the plurality of wires.
Claims
1. A stator for an electric motor, the stator comprising: a body having a plurality of slots; a plurality of wires and insulation extending through the body; as well as at least one insert extending from an outer diameter to an inner diameter of the slot of the body and passing through at least a portion of the plurality of wires, Wherein the at least one insert inhibits relative movement between individual wires of the plurality of wires.
2. The stator of claim 1, wherein the at least one insert comprises a T-shaped portion and a wedge-shaped portion.
3. The stator of claim 1, wherein the at least one insert is made of a plastic material.
4. The stator of claim 1, wherein the at least one insert is made of a ceramic material.
5. The stator of claim 1 further comprising at least one other insert extending from the inner diameter of the slot of the body to a midpoint between the outer diameter and the inner diameter and through a sub-portion of the plurality of wires.
6. The stator of claim 5, wherein each of the at least one insert and the at least one other insert comprises a T-shaped portion and a wedge-shaped portion.
7. A stator as claimed in claim 2 or 6, wherein the T-shaped portion comprises an elongate section.
8. The stator of claim 7, wherein the elongate section is tapered.
9. The stator of claim 5, wherein the at least one insert and the at least one other insert are made of a plastic material.
10. The stator according to claim 3 or 9, wherein the plastic material is polyamideimide, polyphenylene sulfide or polyphenylene oxide.
11. The stator of claim 5, wherein the at least one insert and the at least one other insert are made of a ceramic material.
12. The stator of claim 5, further comprising a mechanism that locks the at least one insert and the another insert together at the midpoint to inhibit movement between individual ones of the plurality of wires.
13. The stator of claim 5, wherein the at least one insert and the at least one other insert are formed as a single integral piece.
14. The stator of claim 5, wherein the at least one insert and the at least one other insert are made from two separate molded pieces.
15. The stator of claim 1, wherein the at least one insert comprises a plurality of spaced-apart inserts.