Stator core, processing method, stator and motor

Abstract

The application discloses a stator core, a processing method, a stator and a motor, and relates to the technical field of electric motors. The stator core comprises a punching sheet assembly, a fixing assembly and a plurality of first connecting pieces. The punching sheet assembly comprises a plurality of punching sheets arranged in an axial direction in a laminated mode, and the punching sheet assembly has a fifth end surface and a sixth end surface opposite to each other in the axial direction. The punching sheet assembly further has a plurality of stator slots arranged at intervals in the axial direction. The fixing assembly is injection molded on the punching sheet assembly. The fixing assembly comprises a first limiting piece, a second limiting piece and the plurality of first connecting pieces. The first limiting piece and the second limiting piece are formed on the fifth end surface and the sixth end surface, respectively. The first connecting pieces are fixedly connected to the first limiting piece and the second limiting piece, and the plurality of first connecting pieces are formed in the respective stator slots. The plurality of punching sheets are fixed under the limiting action of the first limiting piece, the second limiting piece and the first connecting pieces.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to Chinese patent application No. 2025204552391, filed on March 14, 2025, entitled “Stator Structure and Motor”, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This application relates to the technical field of electric motors, and more particularly to a stator core, a processing method, a stator, and an electric motor. Background Technology

[0004] The stator core is one of the important components of an electric motor (such as an AC motor, DC motor, synchronous motor, etc.), and together with the windings, it constitutes the stator.

[0005] The stator core consists of multiple laminations stacked together. In related technologies, the laminations are often fixed together by welding.

[0006] After lamination welding, the iron core has a small outer diameter and a large inner diameter, resulting in a large gap in the inner wall of the iron core, which easily causes large eddy current losses and thus low motor efficiency. Summary of the Invention

[0007] Based on this, this application provides a stator core, a processing method, a stator, and a motor to solve the problem of low motor efficiency in related technologies.

[0008] In a first aspect, embodiments of this application provide a stator core, comprising:

[0009] A lamination assembly includes a plurality of laminations stacked along an axial direction, the lamination assembly having a fifth end face and a sixth end face opposite each other along the axial direction, and the lamination assembly also having a plurality of stator slots spaced apart around the axial direction;

[0010] A fixing component is injection molded onto the lamination assembly; the fixing component includes a first limiting member, a second limiting member, and a plurality of first connecting members; the first limiting member and the second limiting member are respectively formed on the fifth end face and the sixth end face; the first connecting members are fixedly connected to the first limiting member and the second limiting member, and the plurality of first connecting members are respectively formed in each of the stator slots; under the limiting action of the first limiting member, the second limiting member, and the first connecting members, the plurality of laminations are fixed.

[0011] In some embodiments, the first connector is formed on the inner wall of the stator slot.

[0012] In some embodiments, the stator slot has a first sidewall, a second sidewall, and a bottom wall;

[0013] Along the circumferential direction of the lamination assembly, the first sidewall and the second sidewall are opposite to each other; the bottom wall is disposed on the outer periphery of the first sidewall and the second sidewall and is connected to the first sidewall and the second sidewall.

[0014] The first connector is formed on the first sidewall, the second sidewall, and the bottom wall.

[0015] In some embodiments, the stator slot has a groove, and the fixing assembly further includes a second connector, which is formed in the groove and fixedly connected to the first limiting member, the second limiting member and the first connector;

[0016] The first connector and the second connector together form a mounting hole for passing through the stator winding.

[0017] In some embodiments, the first connector and / or the second connector are made of insulating material.

[0018] In some embodiments, guide ramps are provided at both ends of the mounting hole along the axial direction.

[0019] In some embodiments, the number of stator slots is the same as the number of the first connectors, and the stator slots and the first connectors are arranged in a one-to-one correspondence.

[0020] In some embodiments, the lamination assembly includes a toothed assembly and a yoke assembly; along the axial direction of the lamination assembly, the toothed assembly has opposing first and second end faces, and the yoke assembly has opposing third and fourth end faces; the fifth end face includes the first and third end faces, and the sixth end face includes the second and fourth end faces;

[0021] The first limiting member includes:

[0022] Multiple first covering portions, the same number as the toothed components, are formed on the first end face in a one-to-one correspondence with the toothed components;

[0023] A second covering portion is disposed on the outer periphery of the first covering portion and fixedly connected to a plurality of the first covering portions; the second covering portion is formed on the third end face; and / or,

[0024] The second limiting member includes:

[0025] Multiple third covering portions, the same number as the toothed components, are formed on the second end face in a one-to-one correspondence with the toothed components;

[0026] A fourth covering portion is disposed on the outer periphery of the third covering portion and is fixedly connected to the plurality of the third covering portions, and the fourth covering portion is formed on the fourth end face.

[0027] In some embodiments, the first limiting member further includes:

[0028] A fifth covering portion is disposed on the inner periphery of the first covering portion and is fixedly connected to a plurality of the first covering portions, the fifth covering portion being formed on the first end face;

[0029] And / or, the second connector further includes:

[0030] A sixth covering portion is disposed on the inner periphery of the third covering portion and is fixedly connected to the plurality of third covering portions, the sixth covering portion being formed on the second end face.

[0031] In a second aspect, embodiments of this application provide a processing method for processing the stator core described in the first aspect, the method comprising:

[0032] The lamination assembly is annealed.

[0033] The annealed stamping assembly is placed as an insert in the injection mold;

[0034] The fixing component is formed on the surface of the lamination assembly by injection molding to obtain the stator core.

[0035] Thirdly, embodiments of this application provide a stator, including the stator core described in the first aspect.

[0036] Fourthly, embodiments of this application provide an electric motor, including the stator core described in the first aspect or the stator described in the second aspect.

[0037] This application has at least the following beneficial effects:

[0038] The stator core provided in this application uses an integrally injection-molded fixing component on the lamination assembly. After curing, the fixing component, through a first limiting member, a second limiting member, and a first connecting member, jointly limits the laminations of the lamination assembly, ensuring that the laminations are tightly stacked and fixed together. Simultaneously, since the fixing component is injection-molded onto the lamination assembly, the laminations can also be bonded together after molding, improving the connection strength between the laminations. This design allows for a tight fit between the laminations, eliminating gaps. Even if gaps exist, their size is small, ensuring that the flatness of the lamination assembly end face and the stacking height meet design requirements, improving motor efficiency, facilitating winding heat dissipation, and enhancing the coaxiality between the laminations. This avoids problems such as large gaps between laminations, leading to unevenness of the lamination assembly end face and stacking height exceeding drawing requirements, which can occur with welding methods. Furthermore, multiple laminations are fixed in one step using an injection molding process, eliminating the need for sequential fixing of individual laminations as in welding, bonding, or riveting, thus improving the processing efficiency of the stator core. Simultaneously, since the first and second limiting members are respectively formed on two opposite end faces of the lamination assembly along the axial direction, this design also increases the creepage distance of the stator windings. Attached Figure Description

[0039] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0040] Figure 1 This is a schematic diagram of the stator core structure in one or more embodiments of this application. Figure 1 .

[0041] Figure 2 This is a schematic diagram of the stator core structure in one or more embodiments of this application. Figure 2 .

[0042] Figure 3 This is a schematic diagram of the stator core structure in one or more embodiments of this application. Figure 3 .

[0043] Figure 4 This is a schematic diagram of the stator core structure in one or more embodiments of this application. Figure 4 .

[0044] Figure 5 This is a schematic diagram of the structure of the stator core lamination assembly in one or more embodiments of this application. Figure 1 .

[0045] Figure 6 for Figure 5 Enlarged view of point C.

[0046] Figure 7 This is a schematic diagram of the structure of the stator core lamination assembly in one or more embodiments of this application. Figure 2 .

[0047] Figure 8 for Figure 7 Enlarged view of point D in the middle.

[0048] Figure 9 for Figure 2 Enlarged view of point A in the middle.

[0049] Figure 10 for Figure 4 Enlarged view of section B in the middle.

[0050] Figure 11 This is a top view of the lamination assembly of the stator core in one or more embodiments of this application.

[0051] Figure 12 for Figure 11 Enlarged view of point E in the middle.

[0052] Figure 13 This is a top view of the stator core in one or more embodiments of this application.

[0053] Figure 14 for Figure 13 Enlarged view of point F in the middle.

[0054] Figure 15 This is a schematic diagram of the structure of the stator core fixing assembly in one or more embodiments of this application. Figure 1 .

[0055] Figure 16 This is a schematic diagram of the structure of the stator core fixing assembly in one or more embodiments of this application. Figure 2 .

[0056] Figure 17 for Figure 16 Enlarged view of section H in the middle.

[0057] Figure 18 This is a schematic diagram of the structure of the stator core fixing assembly in one or more embodiments of this application. Figure 3 .

[0058] Figure 19 This is a schematic diagram of the structure of the stator core fixing assembly in one or more embodiments of this application. Figure 4 .

[0059] Figure 20 for Figure 19 Enlarged view of section I in the middle.

[0060] Explanation of reference numerals in the attached figures:

[0061] 100-Stator core, 110-Laminated assembly, 110a-Stator slot, 110b-First sidewall, 110c-Second sidewall, 110d-Bottom wall, 110e-Slot opening, 110f-Fifth end face, 110g-Sixth end face, 111-Gear assembly, 111a-First end face, 111b-Second end face, 112-Yoke assembly, 112a-Third end face, 112b-Fourth end face, 120-Fixing assembly, 120a-Mounting hole, 120b-Guide slope, 121-First limiting member, 1211-First cover, 1212-Second cover, 1213-Fifth cover, 122-Second limiting member, 1221-Third cover, 1222-Fourth cover, 1223-Sixth cover, 123-First connector, 124-Second connector. Detailed Implementation

[0062] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions in the embodiments of this application will be described in more detail below with reference to the accompanying drawings. In the drawings, the same or similar reference numerals denote the same or similar components or components having the same or similar functions throughout. The described embodiments are some, but not all, of the embodiments of this application. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application. The embodiments of this application will be described in detail below with reference to the accompanying drawings.

[0063] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, an indirect connection through an intermediate medium, or the internal communication between two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0064] In the description of this application, it should be understood that the terms "upper", "lower", "front", "back", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the accompanying drawings, and are only for the convenience of describing this application and 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, and therefore should not be construed as a limitation of this application.

[0065] The terms “first,” “second,” and “third” (if any) in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence.

[0066] Furthermore, the terms “comprising” and “having”, and any variations thereof, are intended to cover non-exclusive inclusion, such that a process, method, system, product, or display that includes a series of steps or units is not necessarily limited to those steps or units that are explicitly listed, but may include other steps or units that are not explicitly listed or that are inherent to such process, method, product, or display.

[0067] In related technologies, laminations are often fixed together by welding. After welding, the core has a small outer diameter and a large inner diameter, resulting in larger gaps in the inner wall of the core. This easily leads to large eddy current losses, which in turn results in lower motor efficiency.

[0068] In view of this, the inventors designed a stator core 100, a processing method, a stator and a motor. The stator core 100 is fixed by integrally injection molding a fixing component 120 on the lamination assembly 110. After the fixing component 120 is cured, the first limiting member 121, the second limiting member 122 and the first connecting member 123 jointly limit each lamination of the lamination assembly 110, so that the laminations are tightly stacked and fixed together, thereby improving the motor efficiency.

[0069] The stator core 100, processing method, stator and motor provided in the embodiments of this application are described in detail below with reference to the accompanying drawings.

[0070] Please combine Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 11 and Figure 12 As shown, the stator core 100 includes: lamination assembly 110 and fixing assembly 120.

[0071] The lamination assembly 110 includes a plurality of laminations stacked along the axial direction, and the lamination assembly 110 has a fifth end face 110f and a sixth end face 110g that are axially opposite each other. The lamination assembly 110 also has a plurality of stator slots 110a that are axially spaced around the lamination assembly 110.

[0072] It is understandable that the lamination has teeth and yoke. There are multiple teeth that are spaced apart around the axis, and the yoke surrounds the inside or outside of the teeth, connecting all the teeth together.

[0073] When multiple laminations are stacked, the teeth of each lamination are opposite each other along the axial direction, and the yokes of each lamination are also opposite each other along the axial direction. Please refer to... Figure 5As shown, after the teeth of each lamination are stacked, the tooth assembly 111 of the lamination assembly 110 is formed; that is, the tooth assembly 111 of the lamination assembly 110 is formed by stacking the teeth of each lamination. After the yokes of each lamination are stacked, the yoke assembly 112 of the lamination assembly 110 is formed; that is, the yoke assembly 112 of the lamination assembly 110 is formed by stacking the yokes of each lamination. The fifth end face 110f is... Figure 2 The upper end face, the sixth end face, 110g, that is Figure 2 The lower end face of the middle. It can be understood that a stator slot 110a is formed between two adjacent tooth assemblies 111, and the stator slot 110a can be used to accommodate the stator winding.

[0074] The fixing component 120 is injection molded onto the stamping component 110.

[0075] In other words, the stamping assembly 110 is used as an insert placed within the injection mold cavity, and the fixing assembly 120 is directly formed onto the stamping assembly 110 through injection molding. It can be understood that before injection molding, during injection molding, and from the start of injection molding until the plastic solidifies, the injection mold can press the stamping assembly 110 together, ensuring that the individual stamps of the stamping assembly 110 are tightly stacked together. This ensures that after the injection molding plastic solidifies, the individual stamps are tightly stacked and fixed together under the action of the fixing assembly 120. In some embodiments, the individual stamps are bonded together by dispensing adhesive before injection molding.

[0076] The fixing assembly 120 includes a first limiting member 121, a second limiting member 122, and a plurality of first connecting members 123; the first limiting member 121 and the second limiting member 122 are respectively formed on the fifth end face 110f and the sixth end face 110g; the first connecting members 123 are fixedly connected to the first limiting member 121 and the second limiting member 122, and the plurality of first connecting members 123 are respectively formed in each stator slot 110a; under the limiting action of the first limiting member 121, the second limiting member 122 and the first connecting members 123, the plurality of laminations are fixed.

[0077] It should be noted that the first limiting member 121, the second limiting member 122, and multiple first connecting members 123 are integrally injection molded. Please refer to... Figure 1 and Figure 2 As shown, the first limiting member 121 is formed on the fifth end face 110f of the lamination assembly 110, and the first connecting member 123 is formed in the stator slot 110a; please refer to... Figure 3 and Figure 4 As shown, the second limiting member 122 is formed on the sixth end face 110g of the stamping assembly 110. Please refer to... Figure 2 , Figure 4 , Figure 15 , Figure 16 , Figure 18 and Figure 19 As shown, the first connecting member 123 is fixedly connected not only to the first limiting member 121, but also to the second limiting member 122. With this configuration, the first limiting member 121 and the second limiting member 122 are located at opposite ends of the lamination assembly 110 along the axial direction. The first connecting member 123 limits the first limiting member 121 and the second limiting member 122, ensuring that the axial distance between the first limiting member 121 and the second limiting member 122 remains constant. In this way, all laminations located between the first limiting member 121 and the second limiting member 122 are limited by the first limiting member 121 and the second limiting member 122, and the laminations are pressed together tightly, stacked closely, and fixed under the clamping action of the first limiting member 121 and the second limiting member 122.

[0078] It is understandable that the number of first connectors 123 can be less than or equal to the number of stator slots 110a. When the number of first connectors 123 is less than the number of stator slots 110a, a first connector 123 can be provided in some of the stator slots 110a. When the number of first connectors 123 is equal to the number of stator slots 110a, one first connector 123 can be provided in each stator slot 110a.

[0079] The stator core 100 provided in this application uses a fixing component 120 integrally injection-molded onto the lamination assembly 110. After curing, the fixing component 120, through a first limiting member 121, a second limiting member 122, and a first connecting member 123, jointly limits the laminations of the lamination assembly 110, ensuring that the laminations are tightly stacked and fixed together. Simultaneously, since the fixing component 120 is injection-molded onto the lamination assembly 110, it can also bond the laminations together after molding, improving the connection strength between the laminations. This design allows for a tight fit between the laminations, eliminating gaps. Even if gaps exist, their size is small, ensuring that the flatness of the end face of the lamination assembly 110 and the stacking height meet design requirements, improving motor efficiency, facilitating winding heat dissipation, and enhancing the coaxiality between the laminations. This avoids problems such as large gaps between laminations, leading to the flatness of the end face of the lamination assembly 110 and the stacking height exceeding drawing requirements, which can occur with welding methods for fixing the laminations. Furthermore, multiple laminations are fixed at once through the injection molding fixing assembly 120, eliminating the need for sequential fixing of each lamination as in welding, bonding, or riveting, thus improving the processing efficiency of the stator core 100. Simultaneously, since the first limiting member 121 and the second limiting member 122 are respectively formed on two axially opposite end faces of the lamination assembly 110, this design also increases the creepage distance of the stator winding.

[0080] Understandably, please combine Figure 5 , Figure 6 , Figure 7 and Figure 8 As shown, along the axial direction of the lamination assembly 110, the tooth assembly 111 has opposing first end faces 111a and second end faces 111b, and the yoke assembly 112 has opposing third end faces 112a and fourth end faces 112b. The fifth end face 110f includes the first end face 111a and the third end face 112a, and the sixth end face 110g includes the second end face 111b and the fourth end face 112b.

[0081] Please combine Figure 6 and Figure 8 As shown, the upper end face of the tooth assembly 111 is the first end face 111a, and the lower end face is the second end face 111b. The upper end face of the yoke assembly 112 is the third end face 112a, and the lower end face is the fourth end face 112b.

[0082] The first end face 111a and the third end face 112a may be coplanar or not; the second end face 111b and the fourth end face 112b may be coplanar or not, and no limitation is made in this application.

[0083] In some embodiments, please combine Figure 6 As shown, the first end face 111a and the third end face 112a are coplanar. Please refer to... Figure 8 As shown, the second end face 111b and the fourth end face 112b are coplanar.

[0084] Please combine Figure 6 , Figure 9 and 17 As shown, in some embodiments, the first limiting member 121 includes a first cover portion 1211 and a second cover portion 1212. Multiple first cover portions 1211 are provided, matching the number of toothed assemblies 111, and are arranged in a one-to-one correspondence with the toothed assemblies 111, and are formed on the first end face 111a. The second cover portion 1212 is disposed on the outer periphery of the first cover portions 1211 and is fixedly connected to the multiple first cover portions 1211. The second cover portion 1212 is formed on the third end face 112a.

[0085] It is easy to understand that the number of toothed components 111 is the same as the number of teeth on the lamination. A first cover 1211 covers the first end face 111a. The number of first cover 1211 is the same as the number of toothed components 111, and they are arranged in a one-to-one correspondence; that is, each toothed component 111 has a first cover 1211 on its first end face 111a. A second cover 1212 is disposed on the outer periphery of the first cover 1211, that is, the first cover 1211 is disposed inside the second cover 1212. The second cover 1212 is annular and fixedly connected to each of the first cover 1211. The second cover 1212 is formed on the third end face 112a; that is, the second cover 1212 covers the third end face 112a. It should be noted that the second cover 1212 can completely cover the third end face 112a, or it can only cover a portion of it; this application does not impose any limitation on this. Similarly, the first covering portion 1211 can completely cover the first end face 111a, or it can only cover a part of it; this application does not impose any limitations on this.

[0086] With the above design, the first limiting member 121 contacts both the first end face 111a of each toothed assembly 111 and the third end face 112a of the yoke assembly 112. The first limiting member 121 simultaneously limits the toothed assembly 111 and the yoke assembly 112. The contact area between the first limiting member 121 and the lamination assembly 110 is large, which helps to improve the limiting effect of the first limiting member 121 on the lamination assembly 110, so that each lamination fits tightly and reduces lamination deformation.

[0087] Please combine Figure 8 , Figure 10 and Figure 20 As shown, in some embodiments, the second limiting member 122 includes a third cover portion 1221 and a fourth cover portion 1222. Multiple third cover portions 1221 are provided, the number of which corresponds to the number of toothed assemblies 111, and are formed on the second end face 111b in a one-to-one correspondence. The fourth cover portion 1222 is disposed on the outer periphery of the third cover portions 1221 and is fixedly connected to the multiple third cover portions 1221. The fourth cover portion 1222 is formed on the fourth end face 112b.

[0088] The third cover portion 1221 covers the second end face 111b. The number of third cover portions 1221 is the same as the number of toothed assemblies 111, and they are arranged in a one-to-one correspondence, that is, each toothed assembly 111 has a third cover portion 1221 on its second end face 111b. The fourth cover portion 1222 is disposed on the outer periphery of the third cover portion 1221, that is, the third cover portion 1221 is disposed on the inner side of the fourth cover portion 1222. The fourth cover portion 1222 is annular and is fixedly connected to each of the third cover portions 1221. The fourth cover portion 1222 is formed on the fourth end face 112b, that is, the fourth cover portion 1222 covers the fourth end face 112b. It should be noted that the fourth cover portion 1222 can completely cover the fourth end face 112b or cover only part of it, which is not limited in this application. Similarly, the third cover portion 1221 can completely cover the second end face 111b or cover only part of it, which is not limited in this application.

[0089] With the above design, the second limiting member 122 contacts both the second end face 111b of each toothed assembly 111 and the fourth end face 112b of the yoke assembly 112. The second limiting member 122 simultaneously limits the toothed assembly 111 and the yoke assembly 112. The contact area between the second limiting member 122 and the lamination assembly 110 is large, which helps to improve the limiting effect of the second limiting member 122 on the lamination assembly 110, so that each lamination fits tightly and reduces lamination deformation.

[0090] Please combine Figure 6 , Figure 9 and 17 As shown, in some embodiments, the first limiting member 121 further includes a fifth covering portion 1213, which is disposed on the inner periphery of the first covering portion 1211 and fixedly connected to the plurality of first covering portions 1211. The fifth covering portion 1213 is formed on the first end face 111a.

[0091] A fifth cover portion 1213 is disposed inside the first cover portion 1211. The fifth cover portion 1213 is annular and fixes the various first cover portions 1211 together. The fifth cover portion 1213 covers the side of the first end face 111a away from the second cover portion 1212.

[0092] With this design, the fifth cover 1213 and the second cover 1212 are respectively disposed on both sides of the first cover 1211 along the radial direction. The fifth cover 1213 also fixes each of the first cover 1211 together, which strengthens the structural strength of the first limiting member 121. The fifth cover 1213 is also formed on the first end face 111a, which can also limit the stamping assembly 110, improve the overall limiting effect of the first limiting member 121 on the stamping assembly 110, make each stamping fit tightly, and reduce stamping deformation.

[0093] Please combine Figure 8 , Figure 10 and Figure 20 As shown, in some embodiments, the second limiting member 122 further includes a sixth covering portion 1223, which is disposed on the inner periphery of the third covering portion 1221 and fixedly connected to the plurality of third covering portions 1221, and the sixth covering portion 1223 is formed on the second end face 111b.

[0094] A sixth cover portion 1223 is disposed inside the third cover portion 1221. The sixth cover portion 1223 is annular and fixes the third cover portions 1221 together. The sixth cover portion 1223 covers the side of the second end face 111b away from the fourth cover portion 1222.

[0095] With this design, the sixth cover 1223 and the fourth cover 1222 are respectively disposed on both sides of the third cover 1221 along the radial direction. The sixth cover 1223 also fixes each of the third cover 1221 together, which enhances the structural strength of the second limiting member 122. The sixth cover 1223 is also formed on the second end face 111b, which improves the limiting effect of the second limiting member 122 on the stamping assembly 110, so that each stamping fits tightly and reduces stamping deformation.

[0096] In some embodiments, the first connector 123 is formed on the inner wall of the stator slot 110a.

[0097] After the first connector 123 is formed on the inner wall of the stator slot 110a, the first connector 123 can limit the movement of each lamination in the radial or circumferential direction, restrict the movement of the lamination in the radial and circumferential directions, so that the relative position between each lamination is accurate and the stability of the stator core 100 structure is guaranteed.

[0098] Please combine Figure 11 and Figure 12 As shown, in some embodiments, the stator slot 110a has a first sidewall 110b, a second sidewall 110c, and a bottom wall 110d; the first sidewall 110b and the second sidewall 110c are opposite to each other along the circumferential direction of the lamination assembly 110; the bottom wall 110d is disposed on the outer periphery of the first sidewall 110b and the second sidewall 110c and connected to the first sidewall 110b and the second sidewall 110c; the first connector 123 is formed on the first sidewall 110b, the second sidewall 110c, and the bottom wall 110d.

[0099] The first connector 123 is formed on the first sidewall 110b, the second sidewall 110c, and the bottom wall 110d. After forming, as shown... Figure 1 and Figure 3As shown, the first connector 123 completely covers the surfaces of the first sidewall 110b, the second sidewall 110c, and the bottom wall 110d, so that the first sidewall 110b, the second sidewall 110c, and the bottom wall 110d are completely covered.

[0100] With the above design, the first connector 123 serves to limit the movement of each lamination in the radial and circumferential directions, restricting the laminations from moving in the radial and circumferential directions, so that the relative positions between each lamination are accurate, thus ensuring the stability of the stator core 100 structure.

[0101] In some embodiments, the first connector 123 is made of an insulating material.

[0102] The insulating material can be polyethylene, polypropylene, polyvinyl chloride, etc. With this design, the first connector 123 insulates and separates the winding and lamination assembly 110 located inside it. The first connector 123 acts as an insulator between the winding and lamination assembly 110, eliminating the need for insulating paper or other insulating materials between them. This simplifies the structure of the stator core 100, helps reduce manufacturing costs, and avoids the problem of cracking of insulating paper in related technologies. It also allows for a larger winding size (because eliminating insulating paper and other insulating materials frees up space), increasing the copper fill factor in the stator slot 110a and thus improving motor efficiency. Furthermore, the first connector 123 can cover burrs on the inner wall of the stator slot 110a, allowing the laminations to omit the deburring step or reducing deburring requirements, thereby reducing the processing difficulty of the laminations and improving the processing efficiency of the stator core 100.

[0103] As for stator slot 110a, stator slot 110a can be an open slot with slot opening 110e or a closed slot without slot opening 110e, and no limitation is made in this application.

[0104] Please combine Figure 12 , Figure 13 , Figure 14 , Figure 17 , Figure 19 , Figure 20 , Figure 9 and Figure 10 As shown, in some embodiments, the stator slot 110a has a slot 110e, and the fixing assembly 120 further includes a second connector 124. The second connector 124 is formed in the slot 110e and is fixedly connected to the first limiting member 121, the second limiting member 122 and the first connector 123. The first connector 123 and the second connector 124 together form a mounting hole 120a for passing through the stator winding.

[0105] It should be noted that the first limiting member 121, the second limiting member 122, the first connecting member 123, and the second connecting member 124 are integrally injection molded. The second connecting member 124 is fixedly connected to the first limiting member 121, the second limiting member 122, and the first connecting member 123. The second connecting member 124 is formed within the slot 110e, and after forming, the slot 110e is sealed. The second connecting member 124 and the first connecting member 123 together form a mounting hole 120a for passing through the stator winding. The mounting hole 120a is used to accommodate the stator winding, such as... Figure 9 and Figure 10 As shown. The second connector 124 is made of insulating material, which can be polyethylene, polypropylene, polyvinyl chloride, etc. It should be noted that the second connector 124 can be provided in only one or more of the slots 110e, or it can be provided in every slot 110e; this application does not impose any limitation. Figure 1 and Figure 3 As shown, in some embodiments, a second connector 124 is provided in each slot 110e.

[0106] By setting the second limiting member 122, on the one hand, the structural strength of the fixing component 120 can be improved, so that the laminations are firmly fixed together. Specifically, the first limiting member 121 and the second limiting member 122 are connected together by the first connecting member 123 and the second connecting member 124, which improves the structural strength of the fixing component 120 and helps to improve the axial limiting effect of the first limiting member 121 and the second limiting member 122 on the lamination assembly 110, so that each lamination fits tightly and reduces lamination deformation. On the other hand, it can save on the manufacturing cost of the stator core 100. Specifically, due to the design of the second limiting member 122, the stator slot 110a of the lamination assembly 110 does not need to be processed into a closed slot, but can be stamped into an open slot. Later, the slot 110e is sealed by injection molding plastic into the slot and curing it, which helps to reduce the material usage of the lamination assembly 110. Compared with directly stamping into a closed slot, there is no material filling at the opening of the open slot, thus saving the use of metal material, thereby helping to reduce the material usage of the lamination assembly 110 and reduce the manufacturing cost of the stator core 100. Furthermore, since the second connecting member 124 is located inside the slot 110e, the second connecting member 124 can limit each lamination in the radial and circumferential directions. With this design, the first connecting member 123 and the second connecting member 124 jointly restrict the movement of the laminations in the radial and circumferential directions, so that the relative positions between each lamination are accurate and the stability of the stator core 100 structure is guaranteed.

[0107] In some embodiments, the second connector 124 is made of an insulating material.

[0108] The insulating material can be polyethylene, polypropylene, polyvinyl chloride, etc. The second connector 124 is made of insulating material. After the stator winding is installed in the mounting hole 120a, there is no need to install insulating paper or other insulating materials between the stator winding and the second connector 124. This simplifies the structure of the stator core 100, helps to reduce the manufacturing cost of the stator core 100, and also helps to make the winding size design larger (because the insulating paper and other insulating materials are eliminated, some space is freed up), improves the copper fill factor in the stator slot 110a, and thus improves the motor efficiency.

[0109] In some embodiments, along the axial direction, one end of the second connector 124 is connected to the fifth cover portion 1213, such as... Figure 17 As shown, the other end is connected to the sixth cover portion 1223, as... Figure 20 As shown.

[0110] In some embodiments, guide slopes 120b are provided at both ends of the mounting hole 120a along the axial direction. The stator winding is inserted through the openings at both ends of the mounting hole 120a, and the guide slopes 120b are used to guide the stator winding to facilitate insertion of the stator winding into the mounting hole 120a.

[0111] In some embodiments, such as Figure 9 As shown, the first cover portion 1211 and the second cover portion 1212 are provided with guide slopes 120b on the side near the mounting hole 120a, such as... Figure 10 As shown, the third cover 1221, the fourth cover 1222 and the sixth cover 1223 are provided with guide slopes 120b on the side near the mounting hole 120a.

[0112] The shape of the mounting hole 120a is not limited in this application, but its shape is related to the shape of the stator winding. In some embodiments, the cross-section of the stator winding is rectangular, and the cross-section of the mounting hole 120a is also rectangular.

[0113] In some embodiments, the number of stator slots 110a is the same as the number of first connectors 123, and the stator slots 110a and the first connectors 123 are arranged in a one-to-one correspondence.

[0114] In other words, each stator slot 110a is equipped with a first connector 123. This design serves two purposes: First, the first connector 123 in each stator slot 110a can simultaneously limit the radial movement and circumferential misalignment of the laminations at the corresponding positions, making the force on the lamination assembly 110 more balanced along the circumferential direction. This further ensures the coaxiality and end-face flatness of each lamination, reducing problems such as magnetic circuit imbalance caused by lamination position deviations, thereby reducing additional losses and improving motor operating stability. Second, the first connector 123 in each stator slot 110a ensures that the windings in each stator slot 110a are insulated from the lamination assembly 110, avoiding the risk of creepage due to insufficient insulation in individual stator slots 110a.

[0115] Based on the same inventive concept, this application also provides a processing method for processing the above-mentioned stator core 100, the method comprising:

[0116] S100, the lamination assembly 110 is annealed.

[0117] During the stamping process, internal stress is generated due to mechanical deformation, leading to increased material hardness and brittleness. Annealing, by heating to an appropriate temperature, holding at that temperature, and then slowly cooling, can eliminate these stresses, preventing the stamped parts from deforming or cracking due to stress release during subsequent use. Furthermore, annealing reduces lattice defects and impurities within the material, lowering eddy current and hysteresis losses. Annealed grains are refined and more uniformly arranged, increasing magnetic permeability, which allows the motor to generate a stronger magnetic field under the same current, thus improving motor efficiency.

[0118] During annealing, the laminations can be stacked together or not.

[0119] In some embodiments, the annealing temperature is 700–800°C, the holding time is 3.5–4 hours, and an inert gas is used to form a protective atmosphere during the annealing process.

[0120] Setting the annealing temperature to 700–800℃ and holding it for 3.5–4 hours effectively eliminates lattice defects and residual stress within the stamping material through sufficient heating, promoting uniform grain refinement to improve magnetic permeability and reduce iron loss. It also avoids grain coarsening or material performance degradation caused by excessively high temperatures or prolonged holding times. Simultaneously, the use of an inert gas protectant prevents high-temperature oxidation of the stamping, ensuring surface quality. The inert gas can be nitrogen, hydrogen, etc.

[0121] S200, the annealed stamping assembly 110 is placed as an insert in the injection mold.

[0122] It should be noted that before injection molding, during injection molding, and from the start of injection molding until the plastic solidifies, the injection mold can press the stamping assembly 110 together, so that the stampings of the stamping assembly 110 are tightly stacked together. This ensures that after the injection-molded plastic has solidified, the stampings are tightly stacked and fixed together under the action of the fixing assembly 120. In some embodiments, before injection molding, the stampings are bonded together by dispensing adhesive. With this design, the injection mold does not need to press the stamping assembly 110 together.

[0123] S300, the fixing component 120 is formed on the surface of the lamination component 110 by injection molding process to obtain the stator core 100.

[0124] Plastic is poured onto the surface of the lamination assembly 110, and after the plastic cools and solidifies, the stator core is obtained.

[0125] Based on the same inventive concept, this application also provides a stator, including the stator core 100 described above. Since the stator includes the stator core 100 described above, it naturally has all the beneficial effects of the stator core 100, which will not be elaborated here.

[0126] Based on the same inventive concept, this application also provides an electric motor, including the stator core 100 or stator described above. Since the electric motor includes the stator core 100 described above, it naturally has all the beneficial effects of the stator core 100, which will not be elaborated here.

[0127] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A stator core characterized by, include: A lamination assembly (110) includes a plurality of laminations stacked along an axial direction. The lamination assembly (110) has a fifth end face (110f) and a sixth end face (110g) opposite to each other along the axial direction. The lamination assembly (110) also has a plurality of stator slots (110a) spaced apart around the axial direction. A fixing component (120) is injection molded onto the lamination assembly (110); the fixing component (120) includes a first limiting member (121), a second limiting member (122), and a plurality of first connecting members (123); the first limiting member (121) and the second limiting member (122) are respectively formed on the fifth end face (110f) and the sixth end face (110g); the first connecting member (123) is fixedly connected to the first limiting member (121) and the second limiting member (122), and the plurality of first connecting members (123) are respectively formed in each of the stator slots (110a); under the limiting action of the first limiting member (121), the second limiting member (122), and the first connecting member (123), the plurality of laminations are fixed.

2. The stator core according to claim 1, characterized by The first connector (123) is formed on the inner wall of the stator groove (110a).

3. The stator core according to claim 2, characterized in that, The stator slot (110a) has a first sidewall (110b), a second sidewall (110c), and a bottom wall (110d); Along the circumferential direction of the lamination assembly (110), the first sidewall (110b) and the second sidewall (110c) are opposite to each other; the bottom wall (110d) is disposed on the outer periphery of the first sidewall (110b) and the second sidewall (110c) and is connected to the first sidewall (110b) and the second sidewall (110c); The first connector (123) is formed on the first sidewall (110b), the second sidewall (110c) and the bottom wall (110d).

4. The stator core according to claim 3, characterized in that, The stator slot (110a) has a slot (110e), and the fixing assembly (120) further includes a second connector (124), which is formed in the slot (110e) and fixedly connected to the first limiting member (121), the second limiting member (122) and the first connector (123). The first connector (123) and the second connector (124) together form a mounting hole (120a) for passing through the stator winding.

5. The stator core according to claim 4, characterized in that, The first connector (123) and / or the second connector (124) are made of insulating material.

6. The stator core according to claim 4, characterized in that, The mounting hole (120a) is provided with guide slopes (120b) at both ends along the axial direction.

7. The stator core according to any one of claims 1-6, characterized in that, The number of stator slots (110a) is the same as the number of the first connectors (123), and the stator slots (110a) and the first connectors (123) are arranged in a one-to-one correspondence.

8. The stator core according to any one of claims 1-6, characterized in that, The lamination assembly (110) includes a toothed assembly (111) and a yoke assembly (112); along the axial direction of the lamination assembly (110), the toothed assembly (111) has opposing first end faces (111a) and second end faces (111b), and the yoke assembly (112) has opposing third end faces (112a) and fourth end faces (112b); the fifth end face (110f) includes the first end face (111a) and the third end face (112a), and the sixth end face (110g) includes the second end face (111b) and the fourth end face (112b); The first limiting member (121) includes: Multiple first cover portions (1211), the same number as the toothed assembly (111), are formed on the first end face (111a) in a one-to-one correspondence with the toothed assembly (111). A second cover (1212) is disposed on the outer periphery of the first cover (1211) and fixedly connected to a plurality of the first cover (1211), the second cover (1212) being formed on the third end face (112a); and / or, The second limiting member (122) includes: Multiple third cover portions (1221), the same number as the toothed assembly (111), are formed on the second end face (111b) in a one-to-one correspondence with the toothed assembly (111). The fourth cover (1222) is disposed on the outer periphery of the third cover (1221) and is fixedly connected to the plurality of third covers (1221). The fourth cover (1222) is formed on the fourth end face (112b).

9. The stator core according to claim 8, characterized in that, The first limiting member (121) also includes: A fifth covering part (1213) is disposed on the inner periphery of the first covering part (1211) and fixedly connected to a plurality of the first covering parts (1211). The fifth covering part (1213) is formed on the first end face (111a). And / or, the second limiting member (122) further includes: The sixth cover (1223) is disposed on the inner periphery of the third cover (1221) and is fixedly connected to the plurality of third covers (1221). The sixth cover (1223) is formed on the second end face (111b).

10. A processing method, characterized in that, The method for processing the stator core (100) according to any one of claims 1-9 includes: The lamination assembly (110) is annealed. The annealed stamping assembly (110) is placed in the injection mold as an insert; The fixing component (120) is formed on the surface of the lamination assembly (110) by injection molding to obtain the stator core (100).

11. A stator, characterized in that, Includes the stator core (100) according to any one of claims 1-9.

12. An electric motor, characterized in that, Includes the stator core (100) according to any one of claims 1-9 or the stator according to claim 11.

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