Monolithic efficient winding module for spliced motor

Abstract

The invention belongs to the technical field of winding modules, and particularly relates to a monolithic efficient winding module for a block motor, which comprises a stator monolithic. A coil holder is sleeved on the stator single sheet, a winding position is arranged on the coil holder, a lead is wound on the winding position, and the lead comprises a copper foil layer and an insulating layer; the insulating layer is pressed on the copper foil layer. The single-layer insulating layer and the copper foil layer are arranged to replace an existing enameled wire for winding, the thickness is saved, meanwhile, the copper foil has the flat rectangular section, can be tightly attached to the groove wall of the winding position, almost has no gap filling, and is high in copper filling rate, so that the space utilization rate is increased, and the motor efficiency and the power density are high.

Description

Technical Field

[0001] The present invention belongs to the technical field of winding modules, and in particular relates to a single-piece high-efficiency winding module for a modular motor. Background Art

[0002] Traditional winding modules are wound with circular cross-section copper wire (enameled wire), which is commonly found in small and medium-power motors, transformers and inductors. With the development of science and technology, flat wire winding modules have appeared in the fields of new energy and robotics, using flat copper wire with rectangular cross-section (such as hairpin winding). For example, publication number CN215378585U discloses a stator core structure for a traction machine, including a material strip, wherein the material strip is provided with a plurality of wire slots spaced apart along its length, and a winding column is formed between adjacent wire slots. The material strip is spirally stacked to form an iron core, and the iron core is hollow cylindrical. In the process of spirally stacking the material strip to form the iron core, the winding columns overlap to form a winding module for winding coils, which has the effect of facilitating the improvement of the production efficiency of the stator core.

[0003] The aforementioned patent uses traditional enameled wire for winding. While technological advancements have led to the emergence of flat wire winding modules, and while copper filling rates have improved compared to traditional enameled wire winding, they still cannot meet the demands of motors in the new energy and robotics sectors. Issues remain, such as insufficient copper filling rates and low space utilization, resulting in low motor efficiency and power density. Summary of the Invention

[0004] The purpose of the present invention is to provide a monolithic high-efficiency winding module for a block motor, aiming to solve the problem in the above-mentioned background technology that "the copper filling rate of the winding module is insufficient, the space utilization rate is low, resulting in low motor efficiency and low power density".

[0005] To achieve the above-mentioned purpose, an embodiment of the present invention provides a single-piece high-efficiency winding module for a block motor, including a stator single piece; a wire rack is provided on the stator single piece, a winding position is provided on the wire rack, a wire is wound on the winding position, and the wire includes a copper foil layer and an insulating layer; the insulating layer is pressed onto the copper foil layer.

[0006] Optionally, at least one penetrating eddy current suppression groove is provided on the copper foil layer, and the eddy current suppression groove is used to prevent eddy current loss.

[0007] Optionally, the width of the eddy current suppression groove is 0.02 to 0.3 mm.

[0008] Optionally, the eddy current suppression groove is filled with insulating glue, and the insulating glue filling can completely block the conductive path in the eddy current suppression groove.

[0009] Optionally, a lead portion is provided on the copper foil layer, and the lead portion is used for electrical connection.

[0010] Optionally, the wire rack includes a first blocking part and a second blocking part; the first blocking part and the second blocking part are connected by a connecting part, and the winding position is formed between the first blocking part, the second blocking part and the connecting part, and the wire is wound around the connecting part.

[0011] Optionally, the winding position includes two symmetrically arranged avoidance positions; a gap is formed between the two adjacent avoidance positions after the two stator monoliths are spliced, and the gap width gradually narrows from the outside to the inside. When the wire is wound around the wire rack, its winding thickness gradually decreases along the narrowing direction of the gap, so that the outer surface of the wire after winding matches the contour of the avoidance position.

[0012] Optionally, the area of ​​the insulating layer is larger than that of the copper foil layer, so that the insulating layer can completely cover the copper foil layer.

[0013] Optionally, the insulating layer is made of a polymer film or a composite insulating film, and the polymer film is one of polyimide, polyester, polyethylene naphthalate, and polytetrafluoroethylene.

[0014] Optionally, the stator monolith includes a connecting surface; a connecting groove and a connecting protrusion are respectively provided at both ends of the connecting surface, and when the two stator monoliths are spliced ​​together, the connecting protrusion of one stator monolith is plugged into and matched with the connecting groove of the other stator monolith.

[0015] Compared with the prior art, the above one or more technical solutions in the monolithic high-efficiency winding module for the block motor provided by the embodiment of the present invention have at least one of the following technical effects:

[0016] By setting a single-layer insulation layer plus a copper foil layer instead of the existing enameled wire for winding, the thickness is saved. At the same time, the copper foil has a flat rectangular cross-section, which can fit tightly to the slot wall of the winding position, with almost no gap filling and a high copper filling rate, thereby increasing space utilization and making the motor efficiency and power density higher. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0018] Figure 1 Schematic diagram of the conductor structure of the present invention.

[0019] Figure 2Schematic diagram of the conductor layered structure of the present invention.

[0020] Figure 3 Schematic diagram of the structure of the present invention.

[0021] Figure 4 It is a schematic diagram of the explosion structure of the present invention.

[0022] Figure 5 It is a schematic diagram of the combined structure of the present invention.

[0023] Among them, the reference numerals in the figures are:

[0024] 100, stator monolith; 110, connection surface; 111, connection groove; 112, connection protrusion;

[0025] 200, conductor; 210, copper foil layer; 211, eddy current suppression groove; 212, lead end portion; 220, insulation layer.

[0026] 300, wire rack; 310, winding position; 311, avoidance position; 320, first blocking part; 330, second blocking part; 340, connecting part; 350, gap; 360, opening; 370, first split; 380, second split. DETAILED DESCRIPTION

[0027] The following describes embodiments of the present invention in detail, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the embodiments of the present invention, and should not be construed as limiting the present invention.

[0028] In the description of the embodiments of the present invention, it should be understood that the terms "length", "width", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the embodiments of the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention.

[0029] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be understood to indicate or imply relative importance or implicitly specify the number of the technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of the embodiments of the present invention, "plurality" means two or more, unless otherwise specifically defined.

[0030] In the embodiments of the present invention, unless otherwise expressly specified or limited, the terms "installed," "connected," "connected," "fixed," etc. should be understood in a broad sense. For example, they may refer to fixed connection, detachable connection, or integration; mechanical connection or electrical connection; direct connection or indirect connection through an intermediate medium; internal communication between two components or interaction between two components. Those skilled in the art will understand the specific meanings of the above terms in the embodiments of the present invention based on specific circumstances.

[0031] In one embodiment of the present invention, according to Figure 1-5 As shown, it includes a stator monolith 100; a wire rack 300 is sleeved on the stator monolith 100, a winding position 310 is provided on the wire rack 300, a wire 200 is wound on the winding position 310, and the wire 200 includes a copper foil layer 210 and an insulating layer 220; the insulating layer 220 is pressed onto the copper foil layer 210.

[0032] Specifically, by setting a single-layer insulation layer 220 plus a copper foil layer 210 instead of the existing enameled wire for winding, the thickness is saved. At the same time, the copper foil has a flat rectangular cross-section and can fit tightly to the slot wall of the winding position 310, with almost no gap 350 filled, and the copper filling rate is high, thereby increasing space utilization and making the motor efficiency and power density higher.

[0033] Furthermore, the present invention can be used on a motor with a number of turns less than 25.

[0034] Furthermore, the insulating layer 220 is on the upper part of the copper foil layer 210 . When winding, the insulating layer 220 can isolate the copper foil layer 210 from contacting other layers, thereby playing the role of blocking the path.

[0035] Furthermore, the bobbin 300 is a split structure, including two symmetrical parts: a first split part 370 and a second split part 380 . The first split part 370 and the second split part 380 are respectively sleeved on the stator monolith 100 from both ends.

[0036] In another embodiment, Figure 2 As shown, copper foil layer 210 is provided with at least one eddy current suppression groove 211 extending therethrough. This groove 211 is used to prevent eddy current losses. The width of groove 211 is 0.02 to 0.3 mm. Grooves 211 are filled with insulating adhesive, which completely blocks the conductive path within groove 211.

[0037] Specifically, the eddy current suppression grooves 211 divide the continuous copper foil conductor into multiple independent segments, effectively interrupting the closed eddy current loop. Furthermore, the groove width is designed to be in the preferred range of 0.02-0.3 mm, ensuring sufficient conductive cross-sectional area while achieving optimal eddy current suppression. Furthermore, the suppression grooves are completely filled with insulating adhesive, completely blocking potential conductive pathways. This design solves the problem of electric field concentration caused by edge burrs in traditional slotting processes.

[0038] In another embodiment of the present invention, according to Figure 3-5 As shown, the copper foil layer 210 is provided with a lead portion 212 for electrical connection. The wire rack 300 is provided with an opening 360 , and the lead portion 212 can be passed through the opening 360 .

[0039] In another embodiment of the present invention, according to Figure 3-5 As shown, the wire rack 300 includes a first blocking portion 320 and a second blocking portion 330; the first blocking portion 320 and the second blocking portion 330 are connected by a connecting portion 340, and a winding position 310 is formed between the first blocking portion 320, the second blocking portion 330, and the connecting portion 340, and the wire 200 is wound around the connecting portion 340. Specifically, the first blocking portion 320 and the second blocking portion 330 form a winding position 310 with the connecting portion 340 for the wire 200 to be wound.

[0040] In another embodiment of the present invention, according to Figure 3-5 As shown, winding position 310 includes two symmetrically arranged gaps 311. After the two stator monoliths 100 are spliced ​​together, a gap 350 is formed between adjacent gaps 311. The width of gap 350 gradually narrows from the outside to the inside. When the wire 200 is wound around the bobbin 300, its winding thickness gradually decreases along the narrowing direction of gap 350, so that the outer surface of the wound wire 200 matches the contour of the gap 311. Specifically, after winding, the wire 200 can fill the irregular gaps 350, greatly improving the copper filling rate, allowing for more turns, and achieving higher motor efficiency and power density.

[0041] In another embodiment of the present invention, according to Figure 1 and 2 As shown, the area of ​​the insulating layer 220 is larger than the area of ​​the copper foil layer 210, so that the insulating layer 220 can completely cover the copper foil layer 210. The edge of the insulating layer 220 exceeds the boundary of the copper foil layer 210 (exceeding 0.2-2mm), forming a reliable covering structure and completely eliminating the risk of copper foil exposure.

[0042] In another embodiment of the present invention, according to Figure 1 and 2As shown, the insulating layer 220 is made of a polymer film or a composite insulating film, and the polymer film is one of polyimide, polyester, polyethylene naphthalate, and polytetrafluoroethylene. Different films differ in terms of temperature resistance, dielectric strength, conductivity, and flexibility, and each material has different focuses. As a preference, we use an insulating film that meets the requirements of temperature resistance, dielectric strength, conductivity, and flexibility for use in motors. A composite insulating film comprises the following raw materials in the following percentages by weight: 50-60% polyimide resin, 20-30% boron nitride nanosheets, 10-15% toughening agent, 5-8% adhesion promoter, and 3-5% flame retardant. The adhesion promoter is a silane coupling agent, the toughening agent is polyetheretherketone micropowder, and the flame retardant is a phosphate-based halogen-free flame retardant.

[0043] Step 1: Pre-dispersion

[0044] Boron nitride nanosheets and silane coupling agent (KH-550) were mixed at a ratio of 10:1, ultrasonically treated in an ethanol solution for 2 hours, and vacuum-dried at 80°C to obtain a surface-modified boron nitride filler.

[0045] Step 2: Slurry preparation

[0046] Under nitrogen protection, polyimide resin was dissolved in NMP solvent (solid content 30%); modified boron nitride filler and polyetheretherketone powder were added in sequence, and high-speed shear emulsification was performed with a stirring rate of 10,000 rpm and a stirring time of 1 hour; flame retardant was added and stirring was continued until the viscosity reached the standard.

[0047] Step 3: Casting film

[0048] A slit coater was used to coat the surface of copper foil (thickness 0.1-0.3 mm) with a wet film thickness of 100 μm. Stepwise temperature curing was performed: curing at 80°C for 30 minutes, then heating to 150°C for 1 hour, and finally heating to 250°C in a nitrogen atmosphere for 2 hours. Before winding, plasma treatment was performed in an argon atmosphere to enhance surface activity.

[0049] In another embodiment of the present invention, according to Figure 3-5 As shown, the stator monolith 100 includes a connection surface 110; a connection groove 111 and a connection protrusion 112 are respectively provided at both ends of the connection surface 110. When two stator monoliths 100 are spliced ​​together, the connection protrusion 112 of one stator monolith 100 plugs into the connection groove 111 of the other stator monolith 100. Specifically, multiple stator monoliths 100 can be spliced ​​together using the connection groove 111 and connection protrusion 112.

[0050] The above is a further detailed description of the present invention in conjunction with specific preferred embodiments, and the specific implementation of the present invention should not be considered to be limited to these descriptions. For those skilled in the art of the present invention, without departing from the concept of the present invention, its architecture can be flexible and varied, and a series of products can be derived. Simply making a few simple deductions or substitutions should be considered to fall within the scope of patent protection of the present invention as determined by the submitted claims.

Claims

1. A single-piece high-efficiency winding module for a modular motor, characterized in that: The invention comprises a stator monolithic sheet; a wire rack is sleeved on the stator monolithic sheet; a winding position is provided on the wire rack; a conductor is wound on the winding position; the conductor comprises a copper foil layer and an insulating layer; the insulating layer is pressed onto the copper foil layer.

2. The single-piece high-efficiency winding module for the block motor according to claim 1, characterized in that: At least one penetrating eddy current suppression groove is provided on the copper foil layer, and the eddy current suppression groove is used to prevent eddy current loss.

3. The single-piece high-efficiency winding module for the block motor according to claim 2, characterized in that: The width of the eddy current suppression groove is 0.02 to 0.3 mm.

4. The single-piece high-efficiency winding module for the block motor according to claim 2, characterized in that: The eddy current suppression groove is filled with insulating glue, and the insulating glue filling can completely block the conductive path in the eddy current suppression groove.

5. The single-piece high-efficiency winding module for the block motor according to claim 1, characterized in that: The copper foil layer is provided with a lead end portion, and the lead end portion is used for electrical connection.

6. The high-efficiency single-piece winding module for a modular motor according to claim 1, characterized in that: The wire rack includes a first blocking part and a second blocking part; the first blocking part and the second blocking part are connected by a connecting part, and the winding position is formed between the first blocking part, the second blocking part and the connecting part, and the wire is wound around the connecting part.

7. The single-piece high-efficiency winding module for a modular motor according to claim 1, characterized in that: The winding position includes two symmetrically arranged avoidance positions; after the two stator monoliths are spliced, a gap is formed between the two adjacent avoidance positions, and the width of the gap gradually narrows from the outside to the inside. When the wire is wound around the wire rack, its winding thickness gradually decreases along the narrowing direction of the gap, so that the outer surface of the wire after winding matches the contour of the avoidance position.

8. The single-piece high-efficiency winding module for a modular motor according to any one of claims 1 to 7, characterized in that: The area of ​​the insulating layer is larger than that of the copper foil layer, so that the insulating layer can completely cover the copper foil layer.

9. The single-piece high-efficiency winding module for a modular motor according to claim 1, characterized in that: The insulating layer is made of a polymer film or a composite insulating film, and the polymer film is one of polyimide, polyester, polyethylene naphthalate, and polytetrafluoroethylene.

10. The single-piece high-efficiency winding module for a modular motor according to claim 1, characterized in that: The stator monolith includes a connecting surface; the two ends of the connecting surface are respectively provided with a connecting groove and a connecting protrusion. When the two stator monoliths are spliced ​​together, the connecting protrusion of one stator monolith is plugged into and matched with the connecting groove of the other stator monolith.

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