Winding wire structure and motor
By setting grooves and packaging layers on the winding wires to form channels, combining thermoelectric films and heat dissipation layers, the windings are directly cooled, and heat energy is recovered through the temperature difference power generation module, solving the problems of long heat dissipation paths and high space occupancy of the motor, improving heat dissipation efficiency and lightweighting the equipment.
Patent Information
- Application Number
- CN202511042490.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-07-28
- Publication Date
- 2025-10-21
AI Technical Summary
Existing motors are unable to directly exchange heat in the windings, resulting in long heat dissipation paths, high space occupation, and difficulty in resolving the contradiction between insulation and heat dissipation.
Grooves and packaging layers are set on the winding wires to form channels. Combined with thermoelectric films and heat dissipation layers, heat exchange media are directly transported for heat dissipation, and heat energy is recovered through microchannels and temperature difference power generation modules.
It improves the heat dissipation efficiency of the motor, reduces thermal resistance, compresses equipment space, makes the equipment lightweight, and reduces external power supply requirements through heat recovery and utilization.
Smart Images
Figure CN120824976A_ABST
Abstract
Description
Technical Field
[0001] The present invention belongs to the technical field of motors, and in particular relates to a winding wire structure and a motor. Background Art
[0002] During motor operation, the stator winding is one of the main heat generators, generating heat due to various losses, including resistive loss (copper loss) and stray losses (such as skin effect and proximity effect). Resistive loss, the energy loss caused by the resistance of current passing through the winding conductors, is the primary source of winding heat. Stray losses are additional losses caused by uneven current distribution in the winding, non-ideal magnetic fields, and the high-frequency characteristics of alternating current.
[0003] The heat generated by these losses causes the temperature of the motor itself and surrounding components to rise, potentially damaging and aging the insulation, reducing the motor's reliability and lifespan. Traditional cooling technologies (such as air cooling and external liquid cooling) are gradually failing to meet demand due to their large size, low efficiency, and difficulty in locating the heat source. Winding temperature rise has become a key bottleneck restricting performance and reliability. Existing technologies have the following problems:
[0004] 1. Long heat dissipation path: External cooling requires indirect heat conduction through a multi-layer structure (such as iron core and shell), resulting in high thermal resistance;
[0005] 2. High space occupation: External radiators or cooling pipes increase the size of the equipment, limiting the increase in power density;
[0006] 3. Insulation and heat dissipation contradiction: High insulation materials usually have poor thermal conductivity, while high thermal conductivity materials (such as metals) are prone to short circuit risks.
[0007] Therefore, there is an urgent need for an integrated heat dissipation solution that can achieve direct and efficient heat exchange between the heat source and the cooling medium while ensuring insulation reliability.
[0008] Related art discloses an electric motor with auxiliary water cooling and heat dissipation, comprising a motor stator housing, heat dissipation fins and an air cooling device provided on the stator housing, a heat dissipation pipe and a water collecting ring pipe, wherein the heat dissipation pipe is embedded between the heat dissipation fins, and the water collecting ring pipes are provided at both ends of the stator housing. The heat dissipation pipes are connected to the water collecting ring pipes at both ends, one of which is provided with a water inlet pipe, and the other is provided with a drain pipe. The above-mentioned utility model not only increases the size of the equipment due to the heat dissipation fins, air cooling device, and water cooling pipes provided on the stator housing, but also requires indirect heat conduction through a multi-layer structure (such as an iron core and a housing) for external cooling, resulting in high thermal resistance.
[0009] Due to technical problems such as the inability of motors in the prior art to directly exchange heat on the windings, the present invention studies and designs a winding conductor structure and a motor. Summary of the Invention
[0010] Therefore, the present invention provides a winding conductor structure and a motor, which can solve the technical problem in the prior art that the motor cannot directly exchange heat for the winding.
[0011] In order to solve the above problems, the present invention provides a winding conductor structure, including: a copper wire, the copper wire is covered with an insulating layer, a groove is provided on the outer wall of the insulating layer, the groove extends along the length direction of the copper wire, and the groove passes through the insulating layer, an encapsulation layer is provided at the opening of the groove, a channel is formed between the encapsulation layer and the groove, and the channel is used to transport a heat exchange medium.
[0012] In some embodiments, the packaging layer is sleeved on the outer wall of the insulating layer, and a thermoelectric film is provided on the outer wall of the packaging layer.
[0013] In some embodiments, a heat dissipation layer is coated on the thermoelectric film.
[0014] In some embodiments, there are two grooves, and the two grooves are symmetrically distributed 180° around the outer wall of the insulating layer; and / or the grooves are spirally wound around the outer wall of the insulating layer.
[0015] The present invention further provides a motor, comprising a stator, wherein the stator has a winding coil package, and the winding of the winding coil package adopts the aforementioned winding conductor structure.
[0016] In some embodiments, when a heat dissipation layer is coated on the thermoelectric film, the motor further includes a liquid pipe, the channels on the multiple windings of the winding coil are connected in series through the liquid pipe, and the inlet and outlet of the channel are both connected to the liquid pipe.
[0017] In some embodiments, the motor further includes a housing, the stator is located in the housing, and the liquid pipes at the inlet and outlet of the channel both extend out of the housing.
[0018] In some embodiments, a temperature sensor is provided on the shell, and the liquid pipe at the channel inlet is connected to a pump body, and the pump body can control the flow rate of the heat exchange medium in the liquid pipe according to the temperature detected by the temperature sensor.
[0019] In some embodiments, the winding coil has a power lead, which extends out of the shell. With the cross-section of the shell as the projection surface, the liquid pipe at the channel inlet and the power lead are located on the same side. There is a first connecting line between the channel inlet and the center of the shell, and a second connecting line between the outlet of the channel and the center of the shell. There is an angle between the first connecting line and the second connecting line, which satisfies that the angle is 150° to 210°.
[0020] In some embodiments, an energy storage device is further provided on the housing, and the energy storage device is connected to the thermoelectric film.
[0021] The winding conductor structure and motor provided by the present invention have the following beneficial effects:
[0022] By forming a channel between the encapsulation layer and the groove, the heat exchange medium can be transported into the channel to directly exchange heat with the wire. When the winding wire structure of the present invention is applied to the wire of the motor winding, each wire of the winding can be cooled, thereby improving the heat dissipation efficiency of the motor. Placing the heat dissipation system inside the motor can further compress the external space and achieve lightweight equipment. BRIEF DESCRIPTION OF THE DRAWINGS
[0023] To more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for the embodiments or the description of the prior art. The drawings described below are merely exemplary. Those skilled in the art can, without inventive effort, derive other implementation drawings based on the provided drawings.
[0024] Figure 1 It is a structural schematic diagram of the winding wire structure of the present invention;
[0025] Figure 2 is a cross-sectional view of a motor according to another embodiment of the present invention;
[0026] Figure 3 FIG. 4 is a side view of a stator in a motor according to another embodiment of the present invention.
[0027] The accompanying drawings are:
[0028] 1. Copper wire; 2. Insulation layer; 3. Channel; 4. Encapsulation layer; 5. Liquid pipe; 6. Power lead wire; 7. Winding wire package; 8. Stator; 9. Thermoelectric film; 10. Heat dissipation layer; 11. Housing; 12. Energy storage device; 13. Temperature sensor. DETAILED DESCRIPTION
[0029] The following will be combined with the accompanying drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, rather than all the embodiments. The following description of at least one exemplary embodiment is actually only illustrative and is in no way intended to limit the present invention and its application or use. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.
[0030] In the description of the present invention, it should be understood that the directions or positional relationships indicated by directional words such as "front, back, up, down, left, right", "horizontal, vertical, perpendicular, horizontal" and "top, bottom" are usually based on the directions or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description. Unless otherwise specified, these directional words do not indicate or imply that the device or element referred to must have a specific direction or be constructed and operated in a specific direction. Therefore, they cannot be understood as limiting the scope of protection of the present invention; the directional words "inside and outside" refer to the inside and outside relative to the outline of each component itself.
[0031] For ease of description, spatially relative terms such as "above", "above", "on the upper surface of", "above", etc. may be used herein to describe the spatial positional relationship of a device or feature to other devices or features as shown in the figures. It should be understood that spatially relative terms are intended to include different orientations of the device in use or operation in addition to the orientation described in the figures. For example, if the device in the drawings is inverted, the device described as "above other devices or structures" or "above other devices or structures" will be positioned as "below other devices or structures" or "below other devices or structures". Thus, the exemplary term "above" can include both "above" and "below". The device can also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatially relative descriptions used here are interpreted accordingly.
[0032] In addition, it should be noted that the use of terms such as "first" and "second" to limit components is only for the convenience of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore cannot be understood as limiting the scope of protection of the present invention.
[0033] See also Figure 1-3As shown, according to an embodiment of the present invention, a winding conductor structure is provided, comprising: a copper wire 1, wherein the copper wire 1 is coated with an insulating layer 2, a groove is provided on the outer wall of the insulating layer 2, the groove extends along the length direction of the copper wire 1, and the groove passes through the insulating layer 2, an encapsulation layer 4 is provided at the opening of the groove, a channel 3 is formed between the encapsulation layer 4 and the groove, and the channel 3 is used to transport a heat exchange medium.
[0034] In this technical solution, a channel 3 is formed between the encapsulation layer 4 and the groove, and the heat exchange medium can be transported to the channel 3 to directly exchange heat with the wire. When the winding wire structure of the present invention is applied to the wire of the motor winding, each wire of the winding can be cooled, thereby improving the heat dissipation efficiency of the motor. Placing the heat dissipation system inside the motor can further compress the external space and realize lightweight equipment.
[0035] In some embodiments, the packaging layer 4 is sleeved on the outer wall of the insulating layer 2 , and a thermoelectric film 9 is provided on the outer wall of the packaging layer 4 .
[0036] In this technical solution, the encapsulation layer 4 covers the microchannels 3 and is made of a material such as addition-type liquid silicone rubber, which is heat-resistant, has excellent insulation properties, and excellent elasticity. This provides both sealing and secondary insulation. The thermoelectric film 9 adheres closely to the outer surface of the encapsulation layer 4, preventing the risk of electrochemical corrosion caused by direct contact with the coolant.
[0037] In some embodiments, a heat dissipation layer 10 is coated on the thermoelectric film 9 .
[0038] In this technical solution, the thermoelectric film 9 is coated with a heat dissipation layer 10. The outermost layer of the conductive wire is a radiative heat dissipation layer 10, applied to the outside of the thermoelectric film 9. This improves the heat dissipation of the conductive wire and creates a large temperature difference between the inner and outer layers of the thermoelectric film 9. The order of the conductive wires from inside to outside is: copper wire 1 --> insulation layer 2 --> microchannel 3 --> encapsulation layer 4 --> thermoelectric film 9 --> radiative heat dissipation layer 10. Heat dissipation layer 10 can be made of nanomaterials or ceramic materials, specifically nanodiamond coatings or carbon nanotube composites.
[0039] In some embodiments, there are two grooves, and the two grooves are symmetrically distributed 180° around the outer wall of the insulating layer 2; and / or the grooves are spirally wound around the outer wall of the insulating layer 2.
[0040] In this technical solution, a winding insulation layer 2, made of a material such as polyimide, wraps around the copper wire 1 and provides electrical insulation. Two channels 3 are laser-etched into the surface of the insulation layer 2, arranged symmetrically around the circumference at 180°. Alternatively, channels 3 can be arranged in an axial spiral pattern on the surface of the insulation layer 2 to form a flow path for the coolant, increasing the heat dissipation area of the channels 3 from the wire and improving heat dissipation efficiency.
[0041] The present invention further provides a motor, comprising a stator 8 , wherein the stator 8 has a winding coil 7 , and the winding of the winding coil 7 adopts the above-mentioned winding conductor structure.
[0042] In some embodiments, when the thermoelectric film 9 is coated with a heat dissipation layer 10, the motor further includes a liquid pipe 5, the channels 3 on the multiple windings of the winding wire package 7 are connected in series through the liquid pipe 5, and the inlet and outlet of the channel 3 are both connected to the liquid pipe 5.
[0043] In some embodiments, the motor further includes a housing 11 , the stator 8 is located in the housing 11 , and the liquid pipes 5 at the inlet and outlet of the channel 3 both extend out of the housing 11 .
[0044] In this technical solution, the winding coil 7 is wound from n wires containing channels 3 and serves as the core heat source and heat dissipation carrier. The stator 8, constructed from laminated silicon steel sheets, provides magnetic circuit closure and secures the winding coil 7. An external coolant pipe 5 connects to the external circulation system, delivering coolant to the microchannels 3 of the winding coil, thereby cooling the windings through heat exchange. The winding coil 7 is first wound from multiple wires into a coil, which is then stacked. The microchannels 3 on the winding coil are connected in series via the external coolant pipe 5, which delivers and removes the cooling medium from the channels 3.
[0045] The motor of this invention features micron-scale fluid channels etched into the surface of the conductor insulation, directly adjacent to the conductive copper wires, creating the shortest heat transfer path between the coolant and the heat source. Using thermoelectric thin films and thermoelectric power generation modules, thermal energy is converted into electricity through the thermoelectric effect, which is then used to drive other devices, recycling waste heat and improving energy efficiency. Microchannels replace external heat sinks, allowing cooling to be integrated directly into the windings, eliminating the need for additional heat dissipation space.
[0046] In some embodiments, a temperature sensor 13 is provided on the shell 11 , and the liquid pipe 5 at the inlet of the channel 3 is connected to a pump body, which can control the flow rate of the heat exchange medium in the liquid pipe 5 according to the temperature detected by the temperature sensor 13 .
[0047] In this technical solution, the temperature sensor 13 is arranged on the side of the housing 11 where the winding coil 7 has a higher temperature. Different heat dissipation designs may result in different locations with higher temperatures. The location of the terminal in the figure is only an example. Figure 2 The middle position is only an example. The detected temperature of the winding coil 7 is fed back to the external water pump controller. When the temperature exceeds the preset temperature, such as: the temperature of the first stage is 60°C, the temperature of the second stage is 100°C, and the temperature of the third stage is 130°C, the flow rate of the coolant in the microchannel 3 is increased to control the temperature of the winding coil 7.
[0048] In some embodiments, the winding coil 7 has a power lead 6, which extends out of the shell 11. With the cross-section of the shell 11 as the projection surface, the liquid pipe 5 at the inlet of the channel 3 and the power lead 6 are located on the same side. There is a first connecting line between the inlet of the channel 3 and the center of the shell 11, and there is a second connecting line between the outlet of the channel 3 and the center of the shell 11. There is an angle between the first connecting line and the second connecting line, which satisfies that the angle is 150° to 210°.
[0049] In this technical solution, the power lead 6 is used to conduct current, connect to the external circuit, and ensure the normal operation of the motor. The coolant inlet is located at the end of the winding, on the same side as the power lead 6, and the outlet is located on the other side, leading out at the neutral point welding point. The outlet can be led out from any place. The neutral point position is only an example. The angle between the two is 150° to 210°. The coolant inlet and outlet positions can also be reversed for connecting to an external water pump. The stator 8 is made of multiple silicon steel sheets stacked together, with the winding wire package 7 embedded in the slot, and a coolant pipe hole is reserved in the slot. The power lead 6 is welded to the end of the winding using a braided lead wire and is covered with a fluoroplastic insulating sleeve on the outside to ensure the stability and safety of current conduction.
[0050] In some embodiments, an energy storage device 12 is further provided on the housing 11 , and the energy storage device 12 is connected to the thermoelectric film.
[0051] In this technical solution, when the windings generate heat, they heat the inner surface of the thermoelectric film 9, creating a temperature difference with the outer surface of the film. This generates thermoelectric power through the Seebeck effect. The thermoelectric film 9 is connected to an energy storage device 12. The electrons in the thermoelectric film 9 migrate under the influence of the temperature difference, generating a current that flows to the energy storage device 12, which then converges and outputs stable electrical energy. The electrical energy output by the energy storage device 12 can then be fed back to the temperature sensor 13 and the external water pump controller, recycling waste heat and reducing the need for external power supply.
[0052] The motor of this invention significantly improves heat dissipation efficiency and operational reliability by optimizing the winding design and heat dissipation system. By embedding microchannels within the insulation layer of the winding coil, the coolant directly contacts the conductor area, effectively reducing thermal resistance and improving heat dissipation efficiency.
[0053] The motor of the present invention solves the insulation and heat dissipation conflicts caused by the poor thermal conductivity of high-insulation materials and the risk of short circuits in high-insulation materials. It has high heat dissipation efficiency, with only a thin insulation layer separating the heat source and the coolant, allowing for rapid heat dissipation from the windings. It is also compact and has a built-in heat dissipation system, saving space. Beneficial effects include:
[0054] The motor of the present invention adopts a winding heat dissipation structure with microchannels etched in the winding insulation layer, so that the heat source and the coolant are separated by only a thin insulation layer, and the heat of the winding can be quickly discharged. Compared with traditional heat dissipation methods, the thermal resistance of the motor of the present invention is reduced by 50% to 70%, and the heat dissipation efficiency is improved by more than 40%; by placing the heat dissipation system inside the motor, the external space can be further compressed to achieve lightweight equipment; by using thermoelectric effects through thermoelectric films and temperature difference power generation modules, thermal energy is converted into electrical energy for driving other equipment, thereby realizing waste heat recovery and reducing external power supply requirements.
[0055] It is easy for those skilled in the art to understand that, under the premise of no conflict, the advantageous technical features of the above-mentioned methods can be freely combined and superimposed.
[0056] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention. The above description is merely a preferred embodiment of the present invention. It should be noted that those skilled in the art can make various improvements and variations without departing from the technical principles of the present invention, and such improvements and variations shall also be considered within the scope of protection of the present invention.
Claims
1. A winding conductor structure, characterized in that: include: A copper wire (1) is coated with an insulating layer (2), an outer wall of the insulating layer (2) is provided with a groove, the groove extends along the length direction of the copper wire (1), and the groove passes through the insulating layer (2), an encapsulation layer (4) is provided at the opening of the groove, a channel (3) is formed between the encapsulation layer (4) and the groove, and the channel (3) is used to transport a heat exchange medium.
2. The winding conductor structure according to claim 1, characterized in that: The packaging layer (4) is sleeved on the outer wall of the insulating layer (2), and a thermoelectric film (9) is provided on the outer wall of the packaging layer (4).
3. The winding conductor structure according to claim 2, characterized in that: The thermoelectric film (9) is coated with a heat dissipation layer (10).
4. The winding conductor structure according to claim 1, wherein: There are two grooves, and the two grooves are symmetrically distributed in a 180° circumferential direction on the outer wall of the insulating layer (2); and / or the grooves are spirally wound on the outer wall of the insulating layer (2).
5. A motor, characterized in that: include, A stator (8) is provided with a winding coil (7), wherein the winding coil (7) is wound using the winding conductor structure according to any one of claims 1 to 4.
6. The motor according to claim 5, characterized in that: When the thermoelectric film (9) is coated with a heat dissipation layer (10), the motor further comprises a liquid pipe (5), the channels (3) on the plurality of windings of the winding coil (7) are connected in series via the liquid pipe (5), and the inlet and outlet of the channels (3) are both connected to the liquid pipe (5).
7. The motor according to claim 6, characterized in that: The motor further comprises a housing (11), the stator (8) is located in the housing (11), and the liquid pipes (5) at the inlet and outlet of the channel (3) both extend out of the housing (11).
8. The motor according to claim 7, characterized in that: A temperature sensor (13) is provided on the housing (11), and the liquid pipe (5) at the inlet of the channel (3) is connected to a pump body. The pump body can control the flow rate of the heat exchange medium in the liquid pipe (5) according to the temperature detected by the temperature sensor (13).
9. The motor according to claim 6, characterized in that: The winding coil (7) has a power lead (6), and the power lead (6) extends out of the shell (11). With the cross section of the shell (11) as a projection surface, the liquid pipe (5) at the inlet of the channel (3) and the power lead (6) are located on the same side. A first connection line is provided between the inlet of the channel (3) and the center of the shell (11), and a second connection line is provided between the outlet of the channel (3) and the center of the shell (11). An angle is provided between the first connection line and the second connection line, and the angle is 150° to 210°.
10. The motor according to claim 6, characterized in that: An energy storage device (12) is also provided on the housing (11), and the energy storage device (12) is connected to the thermoelectric film.