Efficient heat dissipation motor stator module and manufacturing method thereof

Abstract

The invention discloses an efficient heat dissipation motor stator module and a manufacturing method thereof, and belongs to the technical field of motors. The problems that an existing motor is low in heat dissipation efficiency, high in winding temperature rise and the like are solved. The module comprises a copper winding, a plurality of high-thermal-conductivity ceramic sheets and an independent stator tooth. Comprising a copper winding and stator teeth, any two adjacent wire turns of the copper winding are separated through high-thermal-conductivity ceramic sheets, the stator teeth penetrate through inner holes of the copper winding, and a high-thermal-conductivity epoxy resin potting layer wraps the copper winding, the multiple high-thermal-conductivity ceramic sheets and the part, penetrating into the copper winding, of the stator teeth and is cured into a whole. The high-efficiency heat dissipation stator module provided by the invention can improve the problem of overlarge thermal resistance caused by an air gap and an insulating layer between a winding and an iron core in a traditional motor, constructs a high-efficiency heat conduction path from the winding to the iron core, and effectively improves the heat dissipation performance of the motor.

Description

Technical Field

[0001] This invention belongs to the field of motor technology, and in particular relates to a high-efficiency heat dissipation motor stator module and its manufacturing method. Background Technology

[0002] The electric motor is a core component that converts electrical energy into mechanical energy. During operation, the current flowing through the stator windings generates a significant amount of Joule heat. This heat is the primary source of the motor's temperature rise. In traditional motor structures, the windings are typically round wires covered with insulating varnish. To achieve reliable insulation, insulating material, such as insulating paper, must be placed between the windings and the stator core slot walls. However, due to limitations in the winding and insulating paper curling processes, air gaps inevitably exist between the windings and the insulating paper, and between the insulating paper and the core slot walls. Air, the winding insulating varnish, and the insulating paper all have extremely low thermal conductivity, forming a significant thermal resistance barrier between the windings and the core. The large amount of heat generated by the windings cannot be efficiently transferred to the stator core, leading to excessively high winding temperatures and the formation of localized hot spots. This severely limits the improvement of the motor's power density and overload capacity, and affects the motor's service life and reliability.

[0003] Therefore, how to eliminate or improve the thermal resistance barrier between the winding and the core, and build an efficient heat dissipation path, is a technical bottleneck that the motor industry urgently needs to solve. Summary of the Invention

[0004] The purpose of this invention is to overcome the problems of low heat dissipation efficiency and excessive winding temperature rise caused by excessive thermal resistance between the windings and the core in existing motor stators, and to provide a high-efficiency heat dissipation motor stator module and its manufacturing method. The technical solution adopted by this invention is as follows:

[0005] A high-efficiency heat dissipation motor stator module includes a copper winding and stator teeth. Any two adjacent turns of the copper winding are separated by a high thermal conductivity ceramic sheet. The stator teeth pass through the inner hole of the copper winding. A high thermal conductivity epoxy resin potting layer covers the copper winding, several high thermal conductivity ceramic sheets and the portion of the stator teeth that penetrates the copper winding, and cures them into one piece.

[0006] Furthermore, the copper winding is a rectangular coil made by spirally winding a single flat wire with a rectangular cross-section.

[0007] Furthermore, a high thermal conductivity ceramic sheet is provided between any two adjacent turns on the long side of both sides of the copper winding, and the two sides of the high thermal conductivity ceramic sheet protrude beyond the linewidth of the flat wire.

[0008] Furthermore, the upper and lower surfaces of the high thermal conductivity ceramic sheet are pressed against the corresponding copper winding turns, and the inner surface of the high thermal conductivity ceramic sheet abuts against the stator teeth.

[0009] The present invention also provides a method for manufacturing a high-efficiency heat dissipation motor stator module, wherein the stator module is the aforementioned stator module, comprising the following steps:

[0010] S1: Wind copper windings and prepare several high thermal conductivity ceramic sheets and an independent stator tooth;

[0011] S2: Insert a high thermal conductivity ceramic sheet between any two adjacent turns of the copper winding and assemble it with the independent stator teeth;

[0012] S3: Apply pressure to press several high thermal conductivity ceramic sheets against the corresponding copper winding turns, so that the several high thermal conductivity ceramic sheets are evenly arranged and the inner surface of the several high thermal conductivity ceramic sheets contacts the stator teeth to form the component to be potted.

[0013] S4: The component to be potted is potted using high thermal conductivity epoxy resin;

[0014] S5: The high thermal conductivity epoxy resin is cured to form a high thermal conductivity epoxy resin potting layer. The high thermal conductivity epoxy resin potting layer, copper winding, several high thermal conductivity ceramic sheets and stator teeth form the high-efficiency heat dissipation motor stator module.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0016] 1. Constructing an efficient heat conduction path: This invention creatively inserts a high thermal conductivity ceramic sheet between the upper and lower turns of the winding. The ceramic sheet (such as silicon carbide, aluminum nitride, etc.) has extremely high thermal conductivity and excellent electrical insulation. Heat can be efficiently transferred laterally from the winding to the stator teeth, thus constructing an efficient heat conduction path.

[0017] 2. Replaces insulation layer and air gap: High thermal conductivity epoxy resin potting completely replaces the insulation paper and air gap structure in the traditional motor slot, constructing an auxiliary heat conduction path of "winding → potting layer → stator teeth", which improves the overall thermal conductivity of the module while improving the structural integrity of the module.

[0018] 3. High mechanical strength and modular manufacturing advantages: The integrated modular structure after potting is robust, with strong resistance to vibration and impact, improving the reliability of the motor. The modular structure allows the stator modules to be manufactured and tested independently, simplifying the production process and facilitating automation. Attached Figure Description

[0019] Figure 1 This is a schematic diagram illustrating the fit between the stator module and the stator yoke of the present invention;

[0020] Figure 2 This is a schematic diagram of the assembly of the winding and the high thermal conductivity ceramic sheet;

[0021] Figure 3This is a schematic diagram of the assembly of the windings, high thermal conductivity ceramic sheets, and stator teeth.

[0022] Figure 4 This is a schematic diagram of the high-efficiency heat dissipation motor stator module after potting.

[0023] In the diagram, 1. Copper winding; 2. High thermal conductivity ceramic sheet; 3. Stator teeth; 4. Protruding structure; 5. High thermal conductivity epoxy resin potting layer; 6. Stator yoke. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of this invention clearer, the invention is described below with reference to specific embodiments shown in the accompanying drawings. However, it should be understood that these descriptions are merely exemplary and not intended to limit the scope of the invention. Furthermore, descriptions of well-known structures and technologies are omitted in the following description to avoid unnecessarily obscuring the concept of the invention.

[0025] The connections mentioned in this invention are divided into fixed connections and detachable connections. Fixed connections, also known as non-detachable connections, include but are not limited to conventional fixed connection methods such as folded connections, riveted connections, adhesive connections, and welded connections. Detachable connections include but are not limited to conventional disassembly methods such as bolted connections, snap-fit ​​connections, pin connections, and hinged connections. When a specific connection method is not explicitly defined, it is assumed that at least one existing connection method can be found to achieve this function, and those skilled in the art can choose according to their needs. For example, a welded connection can be chosen for fixed connections, and a bolted connection can be chosen for detachable connections.

[0026] The present invention will be further described in detail below with reference to the accompanying drawings. The following embodiments are explanations of the present invention, but the present invention is not limited to the following embodiments.

[0027] Example 1: As Figures 1-4 As shown, a high-efficiency heat dissipation motor stator module includes a copper winding 1 and independent stator teeth 3. Any two adjacent turns of the copper winding 1 are separated by a high thermal conductivity ceramic sheet 2. The stator teeth 3 pass through the inner hole of the copper winding 1. A high thermal conductivity epoxy resin potting layer 5 covers the copper winding 1, several high thermal conductivity ceramic sheets 2 and the portions of the stator teeth 3 that penetrate into the copper winding 1, and cures them into one piece.

[0028] Copper winding 1 is a rectangular coil made by spirally winding a single flat wire with a rectangular cross-section.

[0029] High thermal conductivity ceramic sheets 2 are provided between any two adjacent turns on the long side of the copper winding 1, and the two sides of the high thermal conductivity ceramic sheets 2 protrude from both sides of the line width of the flat wire.

[0030] The upper and lower surfaces of the high thermal conductivity ceramic sheet 2 are pressed against the corresponding copper winding 1, and the inner surface of the high thermal conductivity ceramic sheet 2 is against the stator tooth 3.

[0031] Example 2: Figures 1-4 As shown, a method for manufacturing a high-efficiency heat dissipation motor stator module, wherein the stator module is the stator module described in Embodiment 1, includes the following steps:

[0032] S1: Wind copper winding 1, and prepare several high thermal conductivity ceramic sheets 2 and an independent stator tooth 3;

[0033] S2: Insert a high thermal conductivity ceramic sheet 2 between any two adjacent turns of the copper winding 1 and assemble it with the independent stator tooth 3.

[0034] S3: Apply pressure to press several high thermal conductivity ceramic sheets 2 against the corresponding copper windings 1, so that the several high thermal conductivity ceramic sheets 2 are evenly arranged, and the inner surface of the several high thermal conductivity ceramic sheets 2 contacts the stator teeth 3 to form the component to be potted.

[0035] S4: The component to be potted is potted with high thermal conductivity epoxy resin, and the high thermal conductivity epoxy resin must completely wet the component.

[0036] S5: The high thermal conductivity epoxy resin is cured to form a high thermal conductivity epoxy resin potting layer 5. The high thermal conductivity epoxy resin potting layer 5, copper winding 1, several high thermal conductivity ceramic sheets 2, and stator teeth 3 form the high-efficiency heat dissipation motor stator module. The assembly is placed in an oven and heated according to the curing curve of the high thermal conductivity epoxy resin to ensure complete curing. After curing, it is demolded to obtain an integrally formed high-efficiency heat dissipation motor stator module.

[0037] Example 3: Figure 1 As shown, a motor stator includes a stator yoke 6 and several high-efficiency heat-dissipating motor stator modules. The root of the stator teeth 3 is provided with a dovetail-shaped protrusion structure 4. The stator yoke 6 is provided with dovetail grooves adapted to the protrusion structure 4. Several high-efficiency heat-dissipating motor stator modules are assembled onto the stator yoke 6 by correspondingly engaging the protrusion structure 4 with the several dovetail grooves of the stator yoke 6, and the electrical connection between the copper windings 1 is completed, thus forming a complete motor stator.

[0038] A high thermal conductivity ceramic sheet 2 is evenly arranged between the upper and lower rectangular turns of the copper winding 1. Under assembly pressure, the upper and lower surfaces of the high thermal conductivity ceramic sheet 2 are tightly pressed into contact with the conductor surface of the copper winding 1, ensuring extremely low contact thermal resistance. Crucially, the inner surface of the high thermal conductivity ceramic sheet 2 (the side facing the stator teeth 3) directly contacts and is pressed against the sidewall of the stator teeth 3.

[0039] As a result, the heat generated by copper winding 1 dissipates outward along two parallel heat dissipation paths:

[0040] Path 1 (Direct Path): Heat is directed from the copper winding 1 to the high thermal conductivity ceramic sheet 2, and then from the inner surface of the high thermal conductivity ceramic sheet 2 to the independent stator teeth 3, thus forming a direct conduction path with all-solid-state and high thermal conductivity.

[0041] Passage 2 (Potting Passage): Heat is drawn from the copper winding 1 and the high thermal conductivity ceramic sheet 2 through the high thermal conductivity epoxy resin potting layer 5 and directed to the stator teeth 3, forming an auxiliary heat dissipation passage.

[0042] Due to the presence of passage one, heat is quickly dissipated, greatly reducing the temperature rise of copper winding 1.

[0043] The advantages of this invention are:

[0044] 1. Constructing an efficient heat conduction path: This invention creatively inserts a high thermal conductivity ceramic sheet between the upper and lower turns of the winding. The ceramic sheet (such as silicon carbide, aluminum nitride, etc.) has extremely high thermal conductivity and excellent electrical insulation. Heat can be efficiently transferred laterally from the winding to the stator teeth, thus constructing an efficient heat conduction path.

[0045] 2. Replaces insulation layer and air gap: High thermal conductivity epoxy resin potting completely replaces the insulation paper and air gap structure in the traditional motor slot, constructing an auxiliary heat conduction path of "winding → potting layer → stator teeth", which improves the overall thermal conductivity of the module while improving the structural integrity of the module.

[0046] 3. High mechanical strength and modular manufacturing advantages: The integrated modular structure after potting is robust, with strong resistance to vibration and impact, improving the reliability of the motor. The modular structure allows the stator modules to be manufactured and tested independently, simplifying the production process and facilitating automation.

[0047] The above embodiments are merely illustrative examples of the present invention and do not limit its scope of protection. Those skilled in the art can make partial changes to them, as long as they do not exceed the spirit and essence of the present invention, they are all within the scope of protection of the present invention.

Claims

1. A high-efficiency heat dissipation motor stator module, characterized in that, The copper winding (1) and stator teeth (3) are included. Any two adjacent turns of the copper winding (1) are separated by a high thermal conductivity ceramic sheet (2). The stator teeth (3) pass through the inner hole of the copper winding (1). The high thermal conductivity epoxy resin potting layer (5) covers the copper winding (1), several high thermal conductivity ceramic sheets (2) and the part of the stator teeth (3) that penetrate into the copper winding (1) and is cured into one piece.

2. The stator module according to claim 1, characterized in that, The copper winding (1) is a rectangular coil made by spirally winding a single flat wire with a rectangular cross section.

3. The stator module according to claim 2, characterized in that, High thermal conductivity ceramic sheets (2) are provided between any two adjacent turns on the long side of the copper winding (1), and the two sides of the high thermal conductivity ceramic sheets (2) protrude from the two sides of the line width of the flat wire.

4. The stator module according to claim 3, characterized in that, The upper and lower surfaces of the high thermal conductivity ceramic sheet (2) are pressed against the turns of the corresponding copper winding (1), and the inner surface of the high thermal conductivity ceramic sheet (2) is pressed against the stator teeth (3).

5. A method for manufacturing a high-efficiency heat-dissipating motor stator module, wherein the stator module is the stator module according to any one of claims 1-4, characterized in that, Includes the following steps: S1: Wind copper windings (1), and prepare several high thermal conductivity ceramic sheets (2) and an independent stator tooth (3). S2: Insert a high thermal conductivity ceramic sheet (2) between any two adjacent turns of the copper winding (1) and assemble it with the independent stator tooth (3); S3: Apply pressure to press several high thermal conductivity ceramic sheets (2) against the turns of the corresponding copper winding (1), so that several high thermal conductivity ceramic sheets (2) are evenly arranged, and the inner surface of several high thermal conductivity ceramic sheets (2) contacts the stator teeth (3) to form the component to be potted; S4: The component to be potted is potted using high thermal conductivity epoxy resin; S5: The high thermal conductivity epoxy resin is cured to form a high thermal conductivity epoxy resin potting layer (5), and the high thermal conductivity epoxy resin potting layer (5), copper winding (1), several high thermal conductivity ceramic sheets (2) and stator teeth (3) form the high efficiency heat dissipation motor stator module.

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