A stator slot oil-cooled insulation structure and drive motor based on foaming inhibitor control

Abstract

This application relates to a stator slot oil-cooled insulation structure and drive motor based on foaming inhibitor control, belonging to the technical field of drive motors, including stator cores and oil-cooled insulation structures. This application utilizes an oil-cooled insulation structure, specifically internal foamed insulation paper that can be combined with epoxy resin strips to form rectangular protruding ends. This creates oil guide grooves between adjacent rectangular protruding ends to facilitate the transfer of cooling oil, thereby achieving efficient oil cooling of the stator windings. Furthermore, the inner recessed end of the rectangular protruding end is also provided with a foamed layer, which expands upon heating to ensure tight contact with the stator windings, achieving a sealed connection and preventing oil leakage. Simultaneously, the foamed insulation paper, through the arrangement of its internal layers, further enhances oil cooling and insulation effects, and through the cooperation of the substrate layer, improves structural strength and extends service life. This significantly improves the heat dissipation and service life of the drive motor.

Description

Technical Field

[0001] This application relates to the field of drive motor technology, and in particular to a stator slot oil-cooled insulation structure and drive motor based on foaming inhibitor control. Background Technology

[0002] The drive motor in an electric vehicle is one of the core components of the entire drive system. Its service life and reliability are directly related to the lifespan and safety of the entire vehicle. During operation, the stator winding coils generate heat due to the current passing through them. If this heat cannot be dissipated in time, it will cause the motor temperature to rise, thereby affecting the motor's performance and lifespan. Therefore, stator winding cooling design is an important aspect of motor design.

[0003] Existing motor winding cooling solutions include reshaping the copper wires inside the stator to create cooling oil channels. However, such solutions often occupy a large area in the slots, significantly reducing the slot fill factor. They also require additional fixing and insulation, and the modification of the winding coils is complex, causing inconvenience to production.

[0004] Furthermore, some existing technologies that incorporate cooling oil channels within stator grooves, by adding a plastic layer or relying on adhesive to partially bond the stator or coil, undoubtedly increase the difficulty and complexity of the manufacturing process due to the limited size of the stator grooves. At the same time, the cooling oil has a certain viscosity, and gaps that are too narrow cannot allow the cooling oil to flow within them, thus failing to achieve an effective cooling effect.

[0005] In response to the aforementioned technologies, there is an urgent need in this field for a stator slot oil-cooled insulation structure and drive motor based on foaming inhibitor control, used for motor winding cooling, allowing the cooling oil to directly contact and circulate to all parts of the stator, which greatly improves the heat dissipation capacity of the windings while having little impact on the slot fill factor. Thus, while fully cooling and insulating the stator, it improves the continuous performance and service life of the motor. Summary of the Invention

[0006] The purpose of this application is to solve the problems of complex manufacturing process and poor heat dissipation and insulation of existing stator slot oil-cooling structures. It provides a stator slot oil-cooling insulation structure and drive motor based on foaming inhibitor control. This stator slot oil-cooling insulation structure improves the stator winding oil cooling effect and extends the service life of the drive motor by optimizing the oil guide groove structure and the insulation structure.

[0007] This application provides a stator slot oil-cooled insulation structure based on foaming inhibitor control, which adopts the following technical solution: It includes a stator core, stator slots are equidistantly spaced inside the stator core, stator windings are located inside the stator slots, and an oil-cooled insulation structure is located inside the stator slots, connected to the outside of the stator windings. The oil-cooled insulation structure includes an epoxy resin shell, which is disposed inside the stator slots. A limiting protrusion is provided in the middle of the epoxy resin shell. Foamed insulating paper is placed inside the epoxy resin shell, epoxy resin strips are provided on the outside of the foamed insulating paper, a foaming layer is filled on the inside of the foamed insulating paper, and ultra-fine glass fiber mesh is provided inside the corners of the foamed insulating paper.

[0008] Preferably, the foamed insulating paper includes a substrate layer, which is located in the middle, and functional coatings are provided on both sides of the outer end of the substrate layer, and an interface treatment layer is provided on the outside of the functional coatings.

[0009] By adopting the above technical solution, namely the combination of substrate layer, functional coating and interface treatment layer, the foaming layer can achieve high-efficiency foaming suppression, high-efficiency heat dissipation assistance and high-temperature and high-pressure insulation.

[0010] Preferably, the joint between the foamed insulating paper and the epoxy resin strip is rectangular and protruding, and an oil guide groove is provided between adjacent protrusions.

[0011] By adopting the above technical solution, namely through the constructed oil guide groove, a circulating oil cooling structure can be formed, which can directly contact the stator winding set in the stator slot to achieve oil cooling heat dissipation. There is no need to add cumbersome components, which greatly reduces the oil cooling process while meeting the requirements of efficient oil cooling heat dissipation.

[0012] Preferably, the rectangular protrusion of the foamed insulating paper is embedded in the inner surface, and the embedded position is coated with a foam layer.

[0013] By adopting the above technical solution, namely by setting a foam layer, the contact effect between the foamed insulation paper and the external shape of the stator winding can be improved. In this way, the oil-cooled insulation structure placed inside the stator slot can be improved, thereby stabilizing the oil cooling and insulation effect of the stator winding.

[0014] Preferably, the substrate layer is formed by mixing para-aramid and meta-aramid in a 3:7 ratio, and 0.1-0.5 wt% silicon carbide nanowires are added inside the substrate layer.

[0015] Preferably, the functional coating is composed of an epoxy resin matrix and a nanocomposite phase, and the epoxy resin matrix is ​​specifically composed of bisphenol A type epoxy and phenolic epoxy in a 4:1 ratio.

[0016] Preferably, the nanocomposite phase specifically includes the following:

[0017] 5-7 wt% hydrophobic fumed silica;

[0018] 3-5 wt% of polydimethylsiloxane-vinyl copolymer;

[0019] Zinc oxide varistor particles, 1-2 wt%.

[0020] Preferably, the interface treatment layer is formed by uniformly spraying and curing a silane coupling agent.

[0021] Preferably, a foaming inhibitor is sprayed on the side of the foamed layer that is in contact with the foamed insulating paper.

[0022] On the other hand, a drive motor comprising the stator described above is also proposed.

[0023] In summary, this application includes at least one of the following beneficial technical effects:

[0024] 1. This application incorporates an oil-cooled insulation structure. The internal foamed insulation paper combines with the external epoxy resin strip to form rectangular protruding ends. This creates oil guide grooves between adjacent rectangular protruding ends, facilitating the transfer of cooling oil and achieving efficient oil cooling of the stator windings. Furthermore, the inner recessed end of the rectangular protruding end is equipped with a foamed layer. This foamed layer expands when heated, ensuring tight contact with the stator windings and achieving a sealed connection, thus preventing oil leakage. Simultaneously, the foamed insulation paper, through its internal layers, further enhances oil cooling and insulation performance. The substrate layer, in conjunction with the foamed insulation paper, improves structural strength and extends service life, thereby significantly improving the heat dissipation and lifespan of the drive motor.

[0025] 2. The foamed insulating paper in this application is composed of a substrate layer, a functional coating layer, and an interface treatment layer. The substrate layer is made by mixing para-aramid and meta-aramid fibers and adding 0.1-0.5 wt% silicon carbide nanowires to improve the tear resistance of the foamed insulating paper. At the same time, the addition of silicon carbide nanowires can form a thermally conductive path to reduce the interfacial thermal resistance and achieve efficient thermal conductivity. The functional coating is made by combining an epoxy resin matrix with a nanocomposite phase. It can work synergistically with silicon carbide nanowires to achieve full-path insulation reinforcement while maintaining the shear strength under high-temperature oil immersion. The interface treatment layer is formed by uniformly spraying and curing a silane coupling agent, which can prevent the penetration of acidic substances in oil to improve the service life of the foamed insulating paper. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the overall structure of this application;

[0027] Figure 2 yes Figure 1A magnified view of part A in the middle;

[0028] Figure 3 yes Figure 1 A magnified view of part B in the middle section;

[0029] Figure 4 This is a schematic diagram of the cross-sectional structure of the oil-cooled insulation structure;

[0030] Figure 5 This is a schematic diagram of the cross-sectional structure of foamed insulating paper.

[0031] Explanation of reference numerals in the attached drawings: 1. Stator core; 2. Stator slot; 3. Stator winding; 4. Oil-cooled insulation structure; 41. Epoxy resin shell; 42. Limiting protrusion; 43. Foamed insulation paper; 431. Substrate layer; 432. Functional coating; 433. Interface treatment layer; 44. Epoxy resin strip; 45. Foamed layer; 46. Oil guide groove; 47. Ultra-fine glass fiber mesh. Detailed Implementation

[0032] The following is in conjunction with the appendix Figure 1 -Appendix Figure 5 This application will be described in further detail below.

[0033] A stator slot oil-cooled insulation structure based on foaming inhibitor control, referring to Figures 1-4 The system includes a stator core 1, with multiple stator slots 2 evenly spaced inside. Stator windings 3 are uniformly wound inside each stator slot 2. Each stator slot 2 has a corresponding oil-cooled insulation structure 4, which is connected to the outer side of each stator winding 3. The oil-cooled insulation structure 4 includes an epoxy resin shell 41, which is located inside the stator slot 2 to ensure structural strength. A limiting protrusion 42 is provided in the middle of the epoxy resin shell 41. The limiting protrusion 42 ensures the stable placement of the subsequent foamed insulation paper 43, preventing loosening. Simultaneously, the limiting protrusion 42 improves the structural strength of the stator slot 2, preventing deformation. Foamed insulation paper 43 is placed inside the epoxy resin shell 41. The insulating paper 43 has epoxy resin strips 44 on each of its outer sides. The epoxy resin strips 44 on the left and right sides of the foamed insulating paper 43 are arranged in a top-bottom pair, while the epoxy resin strips 44 on the top and bottom sides of the foamed insulating paper 43 are arranged as a single strip. The foamed insulating paper 43 is filled with foam layers 45 on all four sides. The corners of the foamed insulating paper 43 are provided with ultra-fine glass fiber mesh 47. The ultra-fine glass fiber mesh 47 enables the foamed insulating paper 43 to have high tensile strength and low thermal expansion on all four sides. This significantly improves the anti-wrinkle ability of the foamed insulating paper 43 on all four sides, thereby improving the stability of the foamed insulating paper 43 when placed inside the stator slot 2, while maintaining high-efficiency insulation performance.

[0034] The foamed insulating paper 43 and the epoxy resin strip 44 are joined in a rectangular protrusion, and an oil guide groove 46 is provided between adjacent protrusions. The oil guide groove 46 formed by this structure can realize the formation of a circulating oil cooling structure, so as to directly contact the stator winding 3 provided in the stator slot 2 to achieve oil cooling heat dissipation. There is no need to add complicated components, which greatly reduces the oil cooling process while meeting the requirements of efficient oil cooling heat dissipation.

[0035] Among them, the foaming layer 45 and the foamed insulating paper 43 are sprayed with foaming inhibitors on the inner contact side. With the foaming inhibitors, the foaming layer 45 can be regularly foamed and make stable and tight contact with the outside of the stator winding 3, thereby improving the connection sealing and reducing oil leakage problems.

[0036] The rectangular protruding end of the foamed insulating paper 43 is embedded in the inner surface, and the embedded position is coated with a foam layer 45. The foam layer 45 improves the contact effect between the foamed insulating paper 43 and the external shape of the stator winding 3, thereby improving the stability of the oil-cooled insulation structure 4 inside the stator slot 2 and achieving the oil cooling and insulation effect of the stator winding 3.

[0037] Reference Figure 5 The foamed insulating paper 43 includes a substrate layer 431, which is located in the middle. Functional coatings 432 are provided on both sides of the outer end of the substrate layer 431. An interface treatment layer 433 is provided on the outside of the functional coatings 432. The combination of the substrate layer 431, the functional coatings 432 and the interface treatment layer 433 can meet the requirements of efficient foaming suppression, efficient heat dissipation assistance and high temperature and high pressure insulation of the foam layer 45.

[0038] The substrate layer 431 is formed by mixing para-aramid and meta-aramid in a 3:7 ratio. 0.1-0.5 wt% silicon carbide nanowires are also added inside the substrate layer 431. This mixture of para-aramid and meta-aramid can improve tear resistance and ensure the overall strength of the substrate layer 431. At the same time, the addition of silicon carbide nanowires can form a thermally conductive path to reduce interfacial thermal resistance and achieve efficient thermal conductivity.

[0039] The functional coating 432 is composed of an epoxy resin matrix and a nanocomposite phase. Specifically, the epoxy resin matrix is ​​composed of bisphenol A type epoxy and phenolic epoxy in a 4:1 ratio. That is, the silicon carbide nanowires in the substrate layer 431 can be combined with the epoxy resin matrix to maintain the shear strength under high temperature oil immersion. At the same time, in conjunction with the silicon carbide nanowires, insulation reinforcement can be achieved throughout the entire path.

[0040] The nanocomposite phases specifically include the following:

[0041] 5-7 wt% hydrophobic fumed silica;

[0042] 3-5 wt% of polydimethylsiloxane-vinyl copolymer;

[0043] Zinc oxide varistor particles, 1-2 wt%.

[0044] Specifically, the addition of hydrophobic fumed silica can form a three-dimensional network structure to suppress coating peeling caused by oil flow shear in the oil guide groove 46, matching the design of the oil guide groove 46. The polydimethylsiloxane-vinyl copolymer can work synergistically with the substrate layer 431 to prevent the propagation of microcracks caused by thermal cycling, while the zinc oxide varistor particles can suppress electric field distortion and build a thermal pathway with the silicon carbide nanowires.

[0045] The interface treatment layer 433 is formed by uniformly spraying and curing a silane coupling agent. The silanol groups generated by the hydrolysis of silane form a hydrogen bond network with the substrate layer 431 to improve the interfacial bonding ability. At the same time, the spraying of the silane coupling agent can prevent the penetration of acidic substances in the oil, thereby improving the service life of the foamed insulating paper 43.

[0046] Specifically, the comparison between the foamed insulation paper used in this application and existing traditional Nomex paper can be seen from the following table:

[0047] Table 1: Performance Comparison Chart of Foamed Insulation Paper of this Application and Existing Traditional Nomex Paper. As can be seen from the table, the foamed insulation paper 43 achieves a synergistic improvement in dielectric strength, thermal conductivity and mechanical strength through aramid fiber compounding optimization, nano-silicon carbide thermal conductivity enhancement and silane interface treatment technology, and its comprehensive performance surpasses that of traditional Nomex paper.

[0048] This application proposes a drive motor comprising a stator as described above. Foamed insulating paper 43 is provided in the stator slot 2. The foamed insulating paper 43, in conjunction with epoxy resin strips 44, forms oil guide grooves 46 between the protrusions, thereby achieving the circulation of cooling oil to meet the efficient oil cooling requirements of the stator windings 3, thus improving the motor's heat dissipation capacity. Simultaneously, the foamed insulating paper 43 occupies little space, requiring no additional modifications to the stator windings 3 or the original internal structure of the motor, simplifying the overall manufacturing process and improving motor performance.

[0049] The embodiments described in this specific implementation are preferred embodiments of this application and are not intended to limit the scope of protection of this application. Identical components are represented by the same reference numerals. Therefore, all equivalent changes made to the structure, shape, and principle of this application should be covered within the scope of protection of this application.

Claims

1. A stator slot oil-cooled insulation structure based on foaming inhibitor control, comprising a stator core (1), stator slots (2) being equidistantly spaced inside the stator core (1), stator windings (3) being disposed inside the stator slots (2), and an oil-cooled insulation structure (4) being disposed inside the stator slots (2), wherein the oil-cooled insulation structure (4) is connected to the outside of the stator windings (3), characterized in that, The oil-cooled insulation structure (4) includes an epoxy resin shell (41), which is located inside the stator slot (2). A limiting protrusion (42) is provided in the middle of the epoxy resin shell (41). Foamed insulation paper (43) is placed inside the epoxy resin shell (41). Epoxy resin strips (44) are provided on the outside of the foamed insulation paper (43). A foamed layer (45) is filled on the inside of the foamed insulation paper (43). Ultra-fine glass fiber mesh (47) is provided inside the corners of the foamed insulation paper (43). The foamed insulating paper (43) and the epoxy resin strip (44) are joined in a rectangular protrusion, and an oil guide groove (46) is provided between adjacent protrusions. The rectangular protruding end of the foamed insulating paper (43) is embedded in the inner surface, and the embedded position is coated with a foam layer (45).

2. The stator slot oil-cooled insulation structure based on foaming inhibitor control according to claim 1, characterized in that, The foamed insulating paper (43) includes a substrate layer (431), which is located in the middle. Functional coatings (432) are provided on both sides of the outer end of the substrate layer (431), and an interface treatment layer (433) is provided on the outer side of the functional coatings (432).

3. The stator slot oil-cooled insulation structure based on foaming inhibitor control according to claim 2, characterized in that, The substrate layer (431) is made by mixing para-aramid and meta-aramid in a 3:7 ratio, and 0.1-0.5wt% silicon carbide nanowires are added inside the substrate layer (431).

4. The stator slot oil-cooled insulation structure based on foaming inhibitor control according to claim 2, characterized in that, The functional coating (432) is composed of an epoxy resin matrix and a nanocomposite phase, and the epoxy resin matrix is ​​specifically composed of bisphenol A type epoxy and phenolic epoxy in a 4:1 ratio.

5. The stator slot oil-cooled insulation structure based on foaming inhibitor control according to claim 4, characterized in that, The nanocomposite phase specifically includes the following: 5-7 wt% hydrophobic fumed silica 3-5 wt% polydimethylsiloxane-vinyl copolymer; 1-2 wt% zinc oxide varistor particles.

6. The stator slot oil-cooled insulation structure based on foaming inhibitor control according to claim 2, characterized in that, The interface treatment layer (433) is formed by uniformly spraying and curing a silane coupling agent.

7. The stator slot oil-cooled insulation structure based on foaming inhibitor control according to claim 1, characterized in that, The foaming layer (45) and the foamed insulating paper (43) are coated with foaming inhibitors on their embedded contact sides.

8. A drive motor comprising a stator as claimed in any one of claims 1-7.

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