Stator core assembly and electric machine

Abstract

This invention relates to the field of motor technology, specifically disclosing a stator core assembly and a motor. The stator core assembly includes a stator core and an insulating shell. The inner circumferential wall of the stator core is provided with multiple winding slots at intervals, and a first cooling hole is provided through the stator core along its axial direction. The insulating shell includes connected insulating end shells and insulating slot shells. The insulating end shells are correspondingly located at opposite ends of the stator core along its axial direction, with each insulating end shell located at a corresponding end of the stator core. The insulating slot shells are correspondingly located at the inner walls of the corresponding winding slots, and the insulating end shells have second cooling holes. The first cooling hole communicates with the two second cooling holes at both ends, forming a cooling channel. The motor includes the aforementioned stator core. The stator core assembly provided in this embodiment has a simple structure and effectively ensures insulation and cooling performance.

Description

Technical Field

[0001] This invention relates to the field of motor technology, and in particular to a stator core assembly and a motor. Background Technology

[0002] In the field of new energy vehicle drive motors, the winding insulation system is one of the core structures ensuring reliable motor operation, and the insulating paper, as a key component of this system, undertakes multiple important functions. First, the insulating paper can achieve effective electrical isolation between the winding and the iron core, windings of different phases, and winding layers, preventing leakage, breakdown, and short circuits under high-voltage conditions, thus building a solid defense for the electrical safety of the motor. Second, the insulating paper can provide mechanical protection for the winding, enabling it to adapt to the complex operating conditions such as high temperature and vibration that the motor often faces during operation, thereby laying the foundation for the long-term stable operation of the motor.

[0003] However, traditional insulating paper has significant shortcomings in meeting the requirements of high-voltage, high-power-density drive motors. On the one hand, traditional insulating paper has poor thermal conductivity and high thermal resistance, making it difficult to quickly dissipate the heat generated by the motor windings during operation. This severely restricts the motor's heat dissipation efficiency, thus affecting its operating performance and service life. On the other hand, the thermal expansion coefficients of traditional insulating paper differ significantly from those of copper windings and iron cores. During the frequent start-stop cycles of the motor, problems such as warping, delamination, and even cracking can easily occur, directly compromising the stability of the insulation system and drastically shortening the motor's service life. Furthermore, these defects cannot be resolved by improving the traditional insulating paper material itself, and have become one of the key bottlenecks hindering the development of new energy vehicle drive motors towards higher power density and greater reliability. Summary of the Invention

[0004] The purpose of this invention is to provide a stator core assembly and motor, which has a simple structure and reliable insulation and cooling performance.

[0005] To achieve this objective, the present invention adopts the following technical solution: A stator core assembly, comprising: The stator core has multiple winding slots spaced apart on its inner peripheral wall, and a first cooling hole is provided through the stator core along its own axial direction. An insulating shell includes an insulating end shell portion and an insulating slot shell portion connected together. The insulating end shell portion is provided one-to-one with the two ends of the stator core that are axially opposite each other. Each insulating end shell portion is provided at the corresponding end of the stator core. The insulating slot shell portion is provided one-to-one with the winding slot. The insulating slot shell portion is provided on the inner wall of the corresponding winding slot. The insulating end shell portion is provided with a second cooling hole. The first cooling hole is connected to the two second cooling holes at both ends and together form a cooling flow channel.

[0006] Preferably, there are multiple first cooling holes, and each of the multiple first cooling holes is disposed on one side of one of the multiple winding slots, and each of the second cooling holes on the insulating end shell is disposed in a one-to-one correspondence with the first cooling hole.

[0007] Preferably, the stator core is formed by stacking multiple stator laminations, each stator lamination having multiple cooling holes, the multiple cooling holes of the multiple stator laminations being connected in a one-to-one correspondence, and multiple sets of connected cooling holes correspondingly forming multiple first cooling holes.

[0008] Preferably, the stator core has a positioning hole at one end, and the insulating end shell has a corresponding positioning head, which is inserted into the positioning hole.

[0009] Preferably, the positioning hole includes a first hole and a second hole, the diameter of the second hole is larger than the diameter of the first hole, the second hole is located inside the first hole, the positioning head includes a first positioning part and a second positioning part disposed at the end of the first positioning part, the diameter of the second positioning part is larger than the diameter of the first positioning part, the first positioning part is located inside the first hole, and the second positioning part is located inside the second hole.

[0010] Preferably, the insulating slot shell is further provided with a sealing head, which is used to seal the slot opening of the winding slot.

[0011] Preferably, the two opposite sidewalls of the insulating groove shell are provided with a plurality of separator heads, and each pair of separator heads is used to separate two adjacent conductors of the winding. The two adjacent conductors and the two separator heads separated between the two conductors together form a first cooling channel.

[0012] Preferably, the insulating slot shell is provided with a groove on the side near the center of the stator core, and the wires in the winding corresponding to the groove and the groove together form a second cooling channel.

[0013] Preferably, the stator core has a positioning hole at one end, and the insulating end shell has a corresponding positioning head, which is inserted into the positioning hole.

[0014] Preferably, the positioning hole includes a first hole and a second hole, the diameter of the second hole is larger than the diameter of the first hole, the second hole is located inside the first hole, the positioning head includes a first positioning part and a second positioning part disposed at the end of the first positioning part, the diameter of the second positioning part is larger than the diameter of the first positioning part, the first positioning part is located inside the first hole, and the second positioning part is located inside the second hole.

[0015] Preferably, the insulating end shell and the insulating groove shell are integrally injection molded.

[0016] An electric motor includes a stator core assembly as described in any of the preceding claims, and further includes a housing, wherein the stator core assembly is disposed within the housing.

[0017] Beneficial effects: In summary, the stator core assembly provided in this embodiment features an insulating shell composed of two insulating end shells and multiple insulating slot shells, replacing the use of insulating paper and achieving precise zoned insulation protection for the stator core. The insulating end shells are fitted to the ends of the stator core, effectively preventing electrical contact between the stator core ends and external components, thus avoiding the risk of end leakage at the source. The insulating slot shells are fitted into the inner walls of the winding slots, forming a reliable insulating barrier between the windings and the stator core, effectively solving the problem of direct contact short circuits between the windings and the slot walls. This double insulation design significantly improves the overall insulation reliability of the stator core assembly, laying a solid foundation for the stable operation of the motor. Furthermore, this application innovatively provides a first cooling hole axially in the stator core and correspondingly opens second cooling holes in the two insulating end shells, allowing the first cooling hole and the two second cooling holes to precisely align and form a complete axial cooling channel. This cooling channel allows coolant to flow through the entire interior of the stator core, directly carrying away heat along its path. Compared to traditional surface cooling methods, this significantly improves heat exchange efficiency and enables rapid control of the stator core's operating temperature within a safe range. Furthermore, the insulation structure and cooling channel design of this stator core assembly are highly integrated, eliminating the need for additional complex auxiliary components. While ensuring insulation and cooling performance, it simplifies the overall structure to the greatest extent, reducing manufacturing costs and assembly difficulty, thus possessing extremely high industrial application value.

[0018] The motor provided in this embodiment includes the stator core assembly described above. It has a simple structure and reliable insulation and cooling performance. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of the stator core assembly provided by the present invention; Figure 2 This is a schematic diagram of the structure of the insulating shell provided by the present invention; Figure 3 This is a schematic diagram of the stator core structure provided by the present invention; Figure 7 This is a partial schematic diagram showing the cooperation between the winding slot and the insulating slot shell portion provided by the present invention; Figure 4 A cross-sectional schematic diagram of the positioning head and positioning hole in one embodiment of the present invention is provided; Figure 5 A cross-sectional schematic diagram of the positioning head and positioning hole in another embodiment of the present invention is provided; Figure 6 A partial schematic diagram of the stator core provided by the present invention; Figure 7 This is a partial schematic diagram of the cooperation between the winding slot and the insulating slot shell portion according to an embodiment of the present invention; Figure 8 This is a partial schematic diagram showing the cooperation between the winding slot and the insulating slot shell portion, according to another embodiment of the present invention.

[0020] In the picture: 1. Stator core; 101. Stator lamination; 11. Winding slot; 12. First cooling hole; 13. Positioning hole; 131. First hole section; 132. Second hole section; 2. Insulating shell; 21. Insulating end shell; 211. Second cooling hole; 212. Positioning head; 2121. First positioning part; 2122. Second positioning part; 22. Insulating groove shell; 221. Separator head; 222. First cooling channel; 223. Groove; 224. Second cooling channel; 225. Sealing head; 3. Wires. Detailed Implementation

[0021] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. The terms "first position" and "second position" refer to two different positions. Furthermore, "above," "on top of," and "over" the first feature in relation to the second feature includes the first feature directly above and diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "under," and "below" the first feature in relation to the second feature includes the first feature directly below and diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0023] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0024] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0025] This invention provides a stator core assembly. (Refer to...) Figures 1 to 8 As shown, the stator core assembly includes a stator core 1 and an insulating shell 2. The stator core 1 has multiple winding slots 11 spaced apart on its inner peripheral wall, and a first cooling hole 12 is provided through the stator core 1 along its axial direction. The insulating shell 2 includes connected insulating end shell portions 21 and insulating slot shell portions 22. The insulating end shell portions 21 are correspondingly arranged at opposite ends of the stator core 1 along its axial direction, with each insulating end shell portion 21 located at a corresponding end of the stator core 1. The insulating slot shell portions 22 are correspondingly arranged at the inner wall of the corresponding winding slot 11, and each insulating end shell portion 21 has a second cooling hole 211. The first cooling hole 12 communicates with the two second cooling holes 211 at both ends, forming a cooling channel.

[0026] In this embodiment, the stator core assembly includes a stator core 1 and an insulating shell 2. The insulating shell 2 includes two insulating end shell portions 21 and multiple insulating slot shell portions 22 located between the two insulating end shell portions 21. The insulating end shell portions 21 are located at the ends of the stator core 1 to ensure the insulation performance of the ends of the stator core 1. The insulating slot shell portions 22 are located on the inner wall of the winding slots 11 to ensure the insulation performance of the winding slots 11. Furthermore, the stator core 1 has a first cooling hole 12 extending through it along its axial direction. Each insulating end shell portion 21 has a second cooling hole 211. The two second cooling holes 211 are respectively connected to the opposite ends of the first cooling holes 12, and the first cooling holes 12 and the two second cooling holes 211 are connected to form a cooling channel. Coolant can flow through the cooling channel, thereby reliably cooling the stator core 1. This stator core assembly has a simple structure and reliable insulation and cooling performance.

[0027] In this embodiment, the insulating end shell 21 and the insulating slot shell 22 are integrally injection molded. Specifically, the injection molding material can fully fill the tiny gaps in the winding slot 11 to form a complete and continuous insulating layer. This layer can replace traditional insulating paper to achieve reliable isolation between the winding and the magnetic core, between phases, and between layers, significantly improving the insulation stability of the motor under high-voltage conditions and effectively avoiding the risk of breakdown, short circuit, and other faults. The integral injection molding structure has superior thermal conductivity, which can significantly reduce the interfacial thermal resistance in the slot, making up for the poor thermal conductivity of traditional insulating paper, effectively improving the heat dissipation of the motor, and ensuring the thermal stability of the motor during long-term operation. In addition, the insulating shell 2 after injection molding is more tightly integrated with the magnetic core and winding, which not only enhances the connection strength of the magnetic core and improves the motor's resistance to vibration and thermal fatigue, but also fundamentally solves the problems of warping, delamination, and cracking caused by the mismatch of thermal expansion coefficients between traditional insulating paper and the winding wires 3 and magnetic core, thus extending the service life of the motor.

[0028] In addition, the circular flange-like structures extending from both ends of the stator core 1 can be connected to the corresponding components (such as oil collectors) to form a cavity, in which the windings are immersed for cooling.

[0029] In this embodiment, multiple first cooling holes 12 are provided, and each of the multiple first cooling holes 12 is correspondingly disposed on one side of a multiple winding slots 11. A second cooling hole 211 on each insulating end shell portion 21 is also correspondingly disposed to a first cooling hole 12. Specifically, multiple cooling channels are correspondingly disposed to multiple winding slots 11, accurately corresponding to the heat-generating parts of the winding slots 11, thereby improving the reliability and effectiveness of heat absorption.

[0030] In this embodiment, the stator core 1 is formed by stacking multiple stator laminations 101. Each stator lamination 101 has multiple cooling holes, and the multiple cooling holes of the multiple stator laminations 101 are connected in a one-to-one manner. Multiple sets of connected cooling holes form multiple first cooling holes 12. Specifically, each cooling channel includes two second cooling holes 211 at both ends, and multiple cooling holes located between the two second cooling holes 211. The multiple connected cooling holes together form a first cooling hole 12.

[0031] In some alternative implementations, refer to Figure 4As shown, the stator core 1 has a positioning hole 13 at one end, and the insulating end shell 21 has a corresponding positioning head 212, which is inserted into the positioning hole 13. Specifically, the fit between the positioning head 212 and the positioning hole 13 enables a tight fit between the end face of the stator core 1 and the corresponding insulating end shell 21, preventing warping and deformation or gaps in the insulating end shells 21 at both ends of the stator core 1 during high-temperature demolding or subsequent high-temperature processes (painting, coating), thereby improving the yield rate. In addition, the insertion fit between the positioning head 212 and the positioning hole 13 also improves the connection reliability between the end face of the stator core 1 and the corresponding insulating end shell 21.

[0032] Specifically, the injection molding material enters the positioning hole 13 through injection molding, and finally forms a solid positioning head 212 in the positioning hole 13.

[0033] Specifically, the positioning hole 13 can be a blind hole or a through hole. The depth, size, and position of the positioning hole 13 should preferably not affect the electromagnetic performance.

[0034] In some alternative implementations, refer to Figures 5 to 6 As shown, the positioning hole 13 includes a first hole portion 131 and a second hole portion 132. The diameter of the second hole portion 132 is larger than the diameter of the first hole portion 131. The second hole portion 132 is located inside the first hole portion 131. The positioning head 212 includes a first positioning portion 2121 and a second positioning portion 2122 disposed at the end of the first positioning portion 2121. The diameter of the second positioning portion 2122 is larger than the diameter of the first positioning portion 2121. The first positioning portion 2121 is located inside the first hole portion 131, and the second positioning portion 2122 is located inside the second hole portion 132. Specifically, this embodiment further corresponds to the injection molding process. When the injection molding material enters the first hole 131 and the second hole 132 through injection molding, and finally forms the solid first positioning part 2121 and the second positioning part 2122 in the positioning hole 13, since the diameter of the second positioning part 2122 is larger than the diameter of the first positioning part 2121, and the diameter of the second hole 132 is larger than the diameter of the first hole 131, the positioning head 212 will not come out of the corresponding end face of the stator core 1, which further improves the installation reliability of the insulating end shell 21 and prevents it from falling off.

[0035] For example, the positioning hole 13 can be formed by opening two adjacent sets of stator laminations 101 at the end. Specifically, the number of stator laminations 101 in each set is set to multiple. The multiple stator laminations 101 in the outer set are each provided with a first hole portion, and all the first hole portions are connected to form a first hole portion 131. The multiple stator laminations 101 in the inner set are each provided with a second hole portion, and all the second hole portions are connected to form a second hole portion 132. When the two sets of stator laminations 101 are stacked, the first hole portion 131 and the second hole portion 132 are connected to each other to form the positioning hole 13.

[0036] In this embodiment, reference is made to Figure 7 As shown, the two opposite sidewalls of the insulating groove shell 22 are each provided with a plurality of separating heads 221, and each pair of corresponding separating heads 221 is used to separate two adjacent conductors 3 of the winding. The two adjacent conductors 3 and the two separating heads 221 separating the two conductors 3 together form a first cooling channel 222. Specifically, the two sidewalls are each provided with a plurality of separating heads 221, and the separating heads 221 are arranged in pairs. The two adjacent conductors 3 of the winding are separated by a pair of two separating heads 221. This arrangement can ensure that the multiple turns of conductors 3 wound in the winding are evenly distributed and reasonably laid out. In addition, the two adjacent conductors 3 and the two separating heads 221 separating the two conductors 3 together form a first cooling channel 222, which further improves the cooling performance of the winding part in the insulating groove.

[0037] In this embodiment, the insulating slot shell 22 has a groove 223 on the side near the center of the stator core 1. The wire 3 in the winding corresponding to the groove 223 and the groove 223 together form a second cooling channel 224. Specifically, the wire 3 in the winding corresponding to the groove 223 is the end wire 3 closest to the center of the stator core 1. This wire 3 and the corresponding groove 223 together form the second cooling channel 224, further improving the cooling performance of the winding part in the insulating slot.

[0038] In this embodiment, the insulating slot shell portion 22 is further provided with a sealing head 225, which is used to seal the slot opening of the winding slot 11. By providing the sealing head 225, the insulation performance of the slot opening portion of the winding slot 11 is effectively guaranteed.

[0039] In some other alternative implementations, refer to Figure 8 As shown, the two opposite sidewalls of the insulating groove shell 22 are not provided with partition heads 221, and are set as smooth wall surfaces.

[0040] This embodiment also provides an electric motor. The electric motor includes the stator core assembly described above, and also includes a housing, in which the stator core assembly is disposed. By using the stator core assembly described above in the electric motor, all the beneficial effects of the stator core assembly described above can be achieved.

[0041] In summary, the stator core assembly provided in this embodiment uses an integrally injection-molded insulating shell 2, which is a combination structure of two insulating end shells 21 and multiple insulating slot shells 22. This replaces the use of insulating paper and achieves precise zoned insulation protection for the stator core 1. The insulating end shells 21 are fitted to the ends of the stator core 1, effectively preventing electrical contact between the ends of the stator core 1 and external components, thus avoiding the risk of end leakage from the source. The insulating slot shells 22 are fitted into the inner wall of the winding slots 11, forming a reliable insulation barrier between the winding and the stator core 1, effectively solving the problem of direct contact short circuits between the winding and the slot wall. This double insulation design significantly improves the overall insulation reliability of the stator core assembly, laying a solid foundation for the stable operation of the motor. Furthermore, this application innovatively provides a first cooling hole 12 axially in the stator core 1 and correspondingly opens second cooling holes 211 in the two insulating end shells 21, allowing the first cooling hole 12 and the two second cooling holes 211 to precisely align and form a complete axial cooling channel. This cooling channel allows the coolant to flow through the entire interior of the stator core 1, directly carrying away heat along its path. Compared to traditional surface cooling methods, this significantly improves heat exchange efficiency and enables the stator core 1 to be quickly controlled within a safe operating range. Furthermore, the insulation structure and cooling channel design of this stator core assembly are highly integrated, eliminating the need for additional complex auxiliary components. While ensuring insulation and cooling performance, this design simplifies the overall structure to the greatest extent possible, reducing manufacturing costs and assembly difficulty, and possesses extremely high industrial application value.

[0042] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A stator core assembly, characterized in that, include: Stator core (1), the inner peripheral wall of the stator core (1) is provided with a plurality of winding slots (11) spaced apart, and the stator core (1) is provided with a first cooling hole (12) through it along its own axial direction. The insulating shell (2) includes an insulating end shell (21) and an insulating slot shell (22) connected to each other. The insulating end shell (21) is provided one-to-one with the two ends of the stator core (1) that are axially opposite to each other. Each insulating end shell (21) is provided at the corresponding end of the stator core (1). The insulating slot shell (22) is provided one-to-one with the winding slot (11). The insulating slot shell (22) is provided on the inner wall of the corresponding winding slot (11). The insulating end shell (21) is provided with a second cooling hole (211). The first cooling hole (12) is connected to the two second cooling holes (211) at both ends and together form a cooling channel.

2. The stator core assembly according to claim 1, characterized in that, The number of the first cooling holes (12) is multiple, and the multiple first cooling holes (12) are respectively arranged on one side of the multiple winding slots (11). The second cooling hole (211) on each insulating end shell (21) is respectively arranged in correspondence with the first cooling hole (12).

3. The stator core assembly according to claim 1, characterized in that, The stator core (1) is formed by stacking multiple stator laminations (101). Each stator lamination (101) has multiple cooling holes. The multiple cooling holes of the multiple stator laminations (101) are connected in a one-to-one manner, and multiple sets of connected cooling holes form multiple first cooling holes (12).

4. The stator core assembly according to claim 1, characterized in that, The stator core (1) is provided with a positioning hole (13) at its end, and the insulating end shell (21) is provided with a positioning head (212) corresponding to it. The positioning head (212) is inserted into the positioning hole (13).

5. The stator core assembly according to claim 4, characterized in that, The positioning hole (13) includes a first hole (131) and a second hole (132). The diameter of the second hole (132) is larger than the diameter of the first hole (131). The second hole (132) is located inside the first hole (131). The positioning head (212) includes a first positioning part (2121) and a second positioning part (2122) disposed at the end of the first positioning part (2121). The diameter of the second positioning part (2122) is larger than the diameter of the first positioning part (2121). The first positioning part (2121) is located inside the first hole (131), and the second positioning part (2122) is located inside the second hole (132).

6. The stator core assembly according to claim 1, characterized in that, The insulating slot shell (22) is also provided with a sealing head (225), which is used to seal the slot opening of the winding slot (11).

7. The stator core assembly according to claim 1, characterized in that, The insulating groove shell (22) has a plurality of separator heads (221) on its two opposite side walls, and each pair of separator heads (221) is used to separate two adjacent wires (3) of the winding. The two adjacent wires (3) and the two separator heads (221) separated between the two wires (3) together form a first cooling channel (222).

8. The stator core assembly according to claim 1, characterized in that, The insulating slot shell (22) has a groove (223) on the side near the center of the stator core (1). The wire (3) in the winding corresponding to the groove (223) and the groove (223) together form a second cooling channel (224).

9. The stator core assembly according to claim 1, characterized in that, The insulating end shell (21) and the insulating groove shell (22) are integrally injection molded.

10. An electric motor, characterized in that, The stator core assembly according to any one of claims 1-9 further includes a housing, wherein the stator core assembly is disposed within the housing.

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