An integrated injection molded stator oil-immersed cooling motor

Abstract

The application discloses an integrated injection-molded stator oil-immersed cooling motor and relates to the technical field of motors.The application comprises a motor shell, the inside of the motor shell is provided with a stator core, the stator slot of the stator core is wrapped with a stator winding, the inner wall, the slot opening, the outer ring and the two ends of the stator slot are all coated with an integrated injection-molded insulator, and the two ends of the integrated injection-molded insulator are provided with through communication oil channels.The integrated injection-molded insulator completely coats the inner wall, the slot opening, the outer ring and the two end faces of the stator slot of the stator core, can replace traditional discrete insulation paper, closes the gap between the stator slot openings, reduces the path of the leakage of the cooling oil from the slot openings, and improves the overall stability of the stator insulation structure; the communication oil channels penetrate through the two ends of the stator in the axial direction, guide the cooling oil to flow uniformly at multiple points of the outer ring of the stator, and make the cooling oil and the outer ring of the stator core form sufficient direct contact.

Description

Technical Field

[0001] This invention relates to the field of motor technology, specifically to an integrated injection-molded stator oil-immersed cooling motor. Background Technology

[0002] Permanent magnet synchronous drive motors, as core power components, are now widely used in various high-end power equipment fields. In the low-altitude economy sector, high-power-density drive motors are the core power units of electric aircraft and eVTOL manned aircraft, with stringent constraints on overall weight and continuous output power, placing high demands on lightweighting and thermal management capabilities. In the field of new energy transportation, high-power permanent magnet motors are used in pure electric passenger cars and commercial vehicles, adapting to vehicle acceleration, hill climbing, and long-term heavy-load operation. In the field of high-end industrial manufacturing, high-speed servo motors serve as actuators in automated equipment, precision machine tools, and industrial robots, maintaining continuous high-speed operation at tens of thousands of revolutions per minute for extended periods. All of these scenarios place high demands on motor power density, heat dissipation performance, operating efficiency, and reliability under multiple operating conditions. The motor's heat dissipation capacity directly constrains the peak and continuous output limits of the entire machine.

[0003] Motor cooling solutions are categorized into three types: air cooling, indirect water cooling, and direct oil cooling. Air cooling is only suitable for low-power, low-heat-generating models. Indirect water cooling relies on heat exchange through the housing's water channels, but the coolant cannot directly contact the windings, resulting in higher thermal resistance and making it difficult to support ultra-high power density designs. Direct oil cooling, with its advantages of excellent insulation and high heat exchange efficiency of cooling oil, has become the mainstream technology for high-power motors, primarily involving oil spray cooling at the stator ends. Oil spray cooling relies on an oil pump to spray cooling oil onto the stator winding ends to complete heat exchange; it has a simple structure and is easy to assemble, and is currently widely used in drive motors for new energy vehicles.

[0004] Current mainstream stator oil spray cooling solutions have significant limitations in their applicability to various scenarios, exhibiting multiple shortcomings under conditions such as aircraft attitude changes, vehicle steep inclines, and long-term high-speed operation of industrial motors. When equipment tilts or shakes, the sprayed cooling oil is prone to flow deviation, with a tendency to seep into the electromagnetic air gap between the stator and rotor. During high-speed rotor rotation, oil trapped in the air gap generates fluid shear resistance, increasing overall oil churning power loss and reducing motor efficiency. Simultaneously, prolonged contact between oil in the air gap and the rotor's permanent magnets increases the probability of magnet corrosion and aging. Continuous oil intrusion into the bearing area also exacerbates the risk of bearing lubrication failure. Furthermore, traditional stators use discrete insulating paper slots with minute gaps at the slot openings, allowing cooling oil to easily leak outwards, further increasing the probability of oil seeping into the rotor cavity. This makes it difficult to simultaneously meet the comprehensive requirements of low loss, high sealing, and all-area heat dissipation for aerospace, automotive, and high-speed industrial equipment. Summary of the Invention

[0005] Based on this, the purpose of the present invention is to provide an integrated injection-molded stator oil-immersed cooling motor to solve the technical problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an integrated injection-molded stator oil-immersed cooling motor, comprising a motor housing, a stator core disposed inside the motor housing, a stator winding wound in the stator slot of the stator core, an integrated injection-molded insulator covering the inner wall, slot opening, outer ring and both ends of the stator slot of the stator core, and both ends of the stator core being covered with an integrated injection-molded insulator, wherein the two ends of the integrated injection-molded insulator are provided with through oil passages, and an insulating sealing assembly is provided between the motor housing and the integrated injection-molded insulator, the insulating sealing assembly comprising a thin-walled metal overlap edge, a sealing ring mounting groove, an annular sealing ring, a first thin-walled ring, an insulating cover plate, an insulating housing end ring and a second thin-walled ring, and a first winding end oil storage cavity and a second winding end oil storage cavity are provided between the integrated injection-molded insulator and the insulating sealing assembly.

[0007] By adopting the above technical solution, the integrated injection-molded insulator completely covers all exposed areas of the stator core, replacing traditional insulating paper and sealing the oil seepage gaps in the slots. The insulating sealing component, together with the shell, encloses two independent oil storage chambers, and the connecting oil passage connects the two oil storage chambers to form a closed oil circuit for the stator. The multi-layer sealing structure can reduce the penetration of cooling oil into the rotor cavity, and the cooling oil only completes full-area circulation and heat exchange within the cavity on the stator side, which is suitable for the harsh heat dissipation conditions of various high-power density power motors.

[0008] Furthermore, the inner side of the motor housing is integrally formed with a thin-walled metal overlap edge, and a sealing ring mounting groove is formed on the outer ring of the thin-walled metal overlap edge. An annular sealing ring is connected inside the sealing ring mounting groove. The two ends of the integral injection-molded insulator are respectively integrally formed with a first thin-walled ring and a second thin-walled ring. The second thin-walled ring, together with the thin-walled metal overlap edge and the inner wall of the motor housing, forms a first winding end oil storage cavity. An insulating cover plate is bonded to one end of the first thin-walled ring. An insulating shell end ring is bonded to the end of the insulating cover plate near the stator core. One end of the insulating shell end ring is bonded to the inner wall of the motor housing. The first thin-walled ring, together with the insulating cover plate, the insulating shell end ring and the inner wall of the motor housing, forms a second winding end oil storage cavity.

[0009] By adopting the above technical solution, the metal thin-walled overlapping edge is combined with the second thin-walled ring and the annular sealing ring to form a radial sealing structure. The first thin-walled ring is combined with the insulating cover plate and the insulating shell end ring to form an end face sealing structure. The bidirectional seals work together to prevent the cooling oil from diffusing into the air gap between the stator and rotor. The two oil storage chambers can completely immerse both ends of the stator winding, thereby increasing the heat exchange area at the end of the winding.

[0010] Furthermore, the outer ring of the motor housing is provided with an oil inlet and an oil outlet, the oil inlet being connected to the oil storage cavity at the end of the first winding, and the oil outlet being connected to the oil storage cavity at the end of the second winding.

[0011] By adopting the above technical solution, the external heat dissipation oil supply system can deliver low-temperature cooling oil to the oil storage chamber at the end of the first winding through the oil inlet, and the high-temperature cooling oil carrying the stator heat can flow back from the oil storage chamber at the end of the second winding to the external oil circuit through the oil outlet, thus establishing a complete closed-loop oil cooling cycle and continuously updating the heat exchange medium to ensure stable heat dissipation.

[0012] Furthermore, the two ends of the connecting oil passage are respectively connected to the oil storage chamber at the end of the first winding and the oil storage chamber at the end of the second winding.

[0013] By adopting the above technical solution, the oil storage chambers on both sides form an interconnected channel through the connecting oil passages. The cooling oil can be evenly distributed to each connecting oil passage and circulate along the stator axis, which expands the contact area between the cooling oil and the stator core and windings, alleviates the problem of local overheating of the stator, and improves the overall heat exchange efficiency.

[0014] Furthermore, the second thin-walled ring is radially sealed to the overlapping edge of the metal thin-walled ring through an annular sealing ring.

[0015] By adopting the above technical solution, the annular sealing ring fills the overlap gap between the second thin-walled ring and the metal thin-walled overlap edge. The sealing ring mounting groove can limit the annular sealing ring, form a stable radial sealing barrier, and reduce the tendency of cooling oil in the oil storage cavity at the end of the first winding to leak to the rotor side.

[0016] Furthermore, the integral injection-molded insulator, the first thin-walled ring, and the second thin-walled ring are all integrally injection-molded using glass fiber reinforced PPS, PEEK, or LCP oil-resistant insulating composite materials, and the insulating cover is made of resin insulating material.

[0017] By adopting the above technical solutions, this type of oil-resistant insulating composite material exhibits lower swelling and cracking after long-term immersion in high-temperature cooling oil, and can maintain insulation and sealing performance for a long time. The thin-walled structure does not significantly expand the equivalent electromagnetic air gap, thus balancing lightweight, insulation reliability, and sealing stability.

[0018] Furthermore, insulating sealant is filled between the insulating cover plate and the first thin-walled ring and the insulating housing end ring, and insulating sealant is filled between the integral injection-molded insulator and the inner wall of the motor housing.

[0019] By adopting the above technical solution, the insulating sealant can fill the gaps between the splicing parts of each component, and after curing, it forms an end face sealing barrier, which forms a two-way isolation and protection with the radial sealing structure, further reducing the possibility of cooling oil spreading to the air gap area of ​​the stator and rotor.

[0020] Furthermore, multiple connecting oil passages are provided, and the multiple connecting oil passages are distributed in a ring array.

[0021] By adopting the above technical solution, the multiple sets of interconnected oil channels arranged in a ring array can allow the cooling oil to be evenly distributed and circumferentially distributed along the stator, avoiding insufficient cooling oil flow in local areas of the stator and achieving uniform heat dissipation throughout the stator core and windings.

[0022] Furthermore, the longitudinal sections of both the first thin-walled ring and the second thin-walled ring are L-shaped, and the first thin-walled ring and the second thin-walled ring are mirror images of each other.

[0023] By adopting the above technical solution, the mirror-arranged L-shaped thin-walled ring can increase the contact surface with the integrated injection-molded insulator, reduce the probability of structural root fracture, and at the same time, the symmetrical sealing structure on both sides can evenly block the leakage of cooling oil, making it suitable for various tilting and shaking operating conditions.

[0024] Furthermore, the inner side of the motor housing is integrally formed with a thin-walled metal overlap edge. An insulating cover plate is bonded to one end of the motor housing and the integral injection-molded insulator. One end of the insulating cover plate, the outer ring of the insulating cover plate, the inner ring of the motor housing, and one end of the integral injection-molded insulator cooperate to form a second winding end oil storage cavity. The outer ring of the thin-walled metal overlap edge and the other end of the integral injection-molded insulator are both provided with sealing ring mounting grooves. An annular sealing ring is connected inside each of the two sealing ring mounting grooves. The inner ring of the motor housing, the outer ring of the thin-walled metal overlap edge, and the other end of the integral injection-molded insulator cooperate to form a first winding end oil storage cavity.

[0025] By adopting the above technical solution, this structure is a lightweight alternative sealing configuration. It eliminates the independent first thin-walled ring, insulating shell end ring and second thin-walled ring. It relies on the insulating cover plate and the integrated injection-molded insulator to directly cooperate with the shell to surround the oil storage cavity. Both sides rely on the annular sealing ring to achieve axial and radial sealing respectively, which simplifies the number of parts and is suitable for the use of lightweight motors in small UAVs.

[0026] Furthermore, the longitudinal section of the insulating cover plate is L-shaped, and insulating sealant is filled between one end of the insulating cover plate, one end of the motor housing, and one end of the integral injection-molded insulator.

[0027] By adopting the above technical solution, the L-shaped insulating cover completes the end shielding, and the sealant fills the gap between the insulating cover, the shell, and the integrated injection-molded insulator, thereby enhancing the overall sealing performance of the oil storage cavity at the end of the second winding and reducing the risk of oil leakage under the operating conditions of small motors.

[0028] Furthermore, the integral injection-molded insulator is axially sealed to the motor housing through one of the annular sealing rings, and the thin-walled metal overlap edge is radially sealed to the motor housing through the other annular sealing ring.

[0029] By adopting the above technical solution, the axial and radial double sealing rings are used to seal the parts in a partitioned manner, respectively preventing the cooling oil in the oil storage chambers on both sides from seeping into the rotor cavity and the outside of the motor housing. This achieves complete separation of the stator oil circuit and the rotor area without the need for multiple layers of thin-walled insulation components.

[0030] In summary, the present invention has the following main beneficial effects:

[0031] 1. This invention, through the integrated injection-molded insulator and the connecting oil channel, completely covers the inner wall of the stator slot, the slot opening, the outer ring, and the end faces of the stator core. It can replace the traditional discrete insulation paper, seal the gap of the stator slot opening, reduce the path of cooling oil leakage from the slot opening, and improve the overall stability of the stator insulation structure. The connecting oil channel runs through both ends of the stator axially, guiding the cooling oil to flow evenly at multiple points on the outer ring of the stator, so that the cooling oil forms full and direct contact with the outer ring of the stator core. Another part of the cooling oil passes through the integrated injection-molded insulator axially and makes full contact with the stator winding, which helps to improve the overall heat exchange efficiency of the motor, alleviate the problem of local overheating of the stator, and support the motor to achieve higher continuous power output.

[0032] 2. This invention utilizes a metal thin-walled overlapping edge, a sealing ring mounting groove, an annular sealing ring, a second thin-walled ring, and an oil storage cavity at the end of the first winding. The metal thin-walled overlapping edge and the second thin-walled ring interlock and cooperate with each other. Relying on the limiting effect of the sealing ring mounting groove on the annular sealing ring, the gap at the overlapping part can be filled to form a radial sealing structure, reducing the tendency of cooling oil to leak into the rotor cavity. The above components, together with the inner wall of the motor housing, form the oil storage cavity at the end of the first winding, which can accommodate cooling oil and immerse the corresponding stator winding end, improving the end heat exchange effect. The thin-walled structure size is adapted to the reference air gap between the stator and rotor, which can reduce the impact on the electromagnetic performance of the motor. The matching oil-resistant material can reduce deformation and cracking under long-term high-temperature oil immersion, maintaining the long-term operational reliability of the sealing structure.

[0033] 3. This invention, through the arrangement of a first thin-walled ring, an insulating cover plate, an insulating shell end ring, and a second winding end oil storage cavity, achieves this by bonding the first thin-walled ring, the insulating cover plate, and the insulating shell end ring together with the inner wall of the motor housing to form the second winding end oil storage cavity. After the contact surface is filled with insulating sealant and cured, it can form an end face sealing barrier, further reducing the possibility of cooling oil penetrating into the stator-rotor air gap area. The end face seal on this side and the radial seal on the other side form a bidirectional isolation protection, which can reduce the oil churning loss caused by oil entering the air gap under multiple operating conditions, help maintain the motor operating efficiency, and reduce the probability of aging and failure of components such as permanent magnets and bearings due to oil influence. The second winding end oil storage cavity can collect the cooling oil flowing through the stator, ensuring smooth oil circulation and meeting the continuous heat dissipation requirements of the motor. Attached Figure Description

[0034] Figure 1This is a schematic diagram of the overall structure of Embodiment 1 of the present invention;

[0035] Figure 2 This is a cross-sectional structural diagram of Embodiment 1 of the present invention;

[0036] Figure 3 This is a partial cross-sectional structural diagram of Embodiment 1 of the present invention;

[0037] Figure 4 This is a schematic diagram of the integrated injection-molded insulator structure according to Embodiment 1 of the present invention;

[0038] Figure 5 This is a cross-sectional structural diagram of Embodiment 2 of the present invention;

[0039] Figure 6 This is a schematic diagram of the integrated insulator end face structure according to Embodiment 2 of the present invention.

[0040] In the diagram: 1. Motor housing; 2. Stator core; 3. Stator winding; 4. Integrated injection-molded insulator; 5. Insulation and sealing assembly; 501. Metal thin-walled overlapping edge; 502. Sealing ring mounting groove; 503. Annular sealing ring; 504. First thin-walled ring; 505. Insulation cover plate; 506. Insulation housing end ring; 507. Second thin-walled ring; 6. Oil storage chamber at the end of the first winding; 7. Oil storage chamber at the end of the second winding; 8. Connecting oil passage; 9. Oil inlet; 10. Oil outlet. Detailed Implementation

[0041] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. 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.

[0042] The embodiments of the present invention will now be described.

[0043] Example 1:

[0044] An integrated injection-molded stator oil-immersed cooling motor, such as Figures 1-4As shown, the device includes a motor housing 1, inside which a stator core 2 is installed. Stator windings 3 are wound within the stator slots of the stator core 2. The stator core 2 and stator windings 3 are the core heat sources for electromagnetic heating of the motor, directly exchanging heat with the cooling oil. The inner wall, slot opening, outer ring, and both ends of the stator slot of the stator core 2 are all covered with an integrated injection-molded insulator 4. The integrated injection-molded insulator 4 completely covers all exposed areas of the stator core 2, sealing the leakage gaps at the stator slot openings and improving overall insulation stability. The gap between the integrated injection-molded insulator 4 and the inner wall of the motor housing 1 is filled with insulating sealant. The insulating sealant also fills the assembly gap of the outer ring, reducing the tendency for cooling oil to leak outwards along the gaps. Through-flow oil channels 8 are opened at both ends of the integrated injection-molded insulator 4. The motor housing 1 and a... An insulating sealing component 5 is provided between the integral injection molded insulators 4. A first winding end oil storage cavity 6 and a second winding end oil storage cavity 7 are provided between the integral injection molded insulators 4 and the insulating sealing component 5. The two ends of the connecting oil channel 8 are respectively connected to the first winding end oil storage cavity 6 and the second winding end oil storage cavity 7. Multiple connecting oil channels 8 are provided, and the multiple connecting oil channels 8 are distributed in a ring array. Multiple sets of ring array connecting oil channels 8 form an axial flow channel to achieve uniform oil distribution and heat dissipation in the stator circumferential direction. An oil inlet 9 and an oil outlet 10 are respectively opened on the outer ring of the motor housing 1. The oil inlet 9 is connected to the first winding end oil storage cavity 6, and the oil outlet 10 is connected to the second winding end oil storage cavity 7. The oil inlet 9 and the oil outlet 10 are respectively connected to the external oil circuit to form a complete oil cooling circulation loop.

[0045] See Figures 1-3 In the above embodiments, the insulating sealing assembly 5 includes a thin-walled metal overlap edge 501, a sealing ring mounting groove 502, an annular sealing ring 503, a first thin-walled ring 504, an insulating cover plate 505, an insulating housing end ring 506, and a second thin-walled ring 507.

[0046] Specifically, the inner side of the motor housing 1 is integrally formed with a thin-walled metal overlapping edge 501. A sealing ring mounting groove 502 is formed on the outer circumference of the thin-walled metal overlapping edge 501. An annular sealing ring 503 is connected inside the sealing ring mounting groove 502. The sealing ring mounting groove 502 provides circumferential restraint to the annular sealing ring 503, ensuring the stability of the sealing element's position. The two ends of the integral injection-molded insulator 4 are respectively integrally formed with a first thin-walled ring 504 and a second thin-walled ring 507. The integral injection-molded insulator 4, the first thin-walled ring 504, and the second thin-walled ring 507... Both are integrally injection molded using glass fiber reinforced PPS, PEEK, or LCP oil-resistant insulating composite materials. This material is resistant to high-temperature oil immersion, reducing swelling and cracking during long-term operation. The longitudinal sections of the first thin-walled ring 504 and the second thin-walled ring 507 are both L-shaped, and the first thin-walled ring 504 and the second thin-walled ring 507 are mirror images of each other. The symmetrical L-shaped structure increases the bonding area with the integral injection-molded insulator 4, alleviating structural fracture problems. The second thin-walled ring 507 is radially sealed to the metal thin-walled overlap edge 501 through the annular sealing ring 503. The annular sealing ring 503 fills the overlapping gap, constructing a single-sided radial sealing barrier; the second thin-walled ring 507, together with the metal thin-walled overlapping edge 501 and the inner wall of the motor housing 1, forms the first winding end oil storage cavity 6, which contains cooling oil and immerses one end of the stator winding 3, enhancing the end heat exchange effect; an insulating cover plate 505 is bonded to one end of the first thin-walled ring 504, which is made of resin insulating material, and an insulating shell end ring 50 is bonded to the end of the insulating cover plate 505 near the stator core 2. 6. One end of the insulating housing end ring 506 is bonded to the inner wall of the motor housing 1. The space between the insulating cover plate 505, the first thin-walled ring 504, and the insulating housing end ring 506 is filled with insulating sealant. The first thin-walled ring 504, the insulating cover plate 505, the insulating housing end ring 506, and the inner wall of the motor housing 1 cooperate to form the second winding end oil storage cavity 7. The insulating cover plate 505, the insulating housing end ring 506, and the first thin-walled ring 504 form an end face sealing structure. The second winding end oil storage cavity 7 collects the cooling oil after heat exchange and wraps the other winding end.

[0047] The implementation principle of this embodiment is as follows: First, the stator core 2 and stator winding 3 serve as the existing basic structure for the electromagnetic energy conversion of the motor. After the stator winding 3 is supplied with three-phase alternating current, a rotating magnetic field is formed under the magnetic guidance of the stator core 2. The rotor is driven to rotate continuously through electromagnetic induction, converting electrical energy into mechanical energy to output power. During the operation, the stator winding 3 and stator core 2 will continuously generate heat loss. Meanwhile, the low-temperature cooling oil supplied by the external heat dissipation oil supply system enters directly into the first winding end oil storage cavity 6, which is formed by the metal thin-walled overlapping edge 501, the second thin-walled ring 507, and the inner wall of the motor housing 1. After entering the cavity, the cooling oil diffuses evenly, fully immersing the corresponding end of the stator winding 3, directly contacting the surface of the winding end and quickly absorbing the heat generated by the winding. At the same time, part of the cooling oil is diverted into multiple sets of interconnecting oil channels 8 arranged in a ring array, flowing along the stator axis from the first winding end oil storage cavity 6 side to the second winding end oil storage cavity 7 side. Another part of the cooling oil flows from the gap between the stator winding 3 and the integrated injection-molded insulator 4 to the second winding end oil storage cavity 7 side. During the flow of the cooling oil in the interconnecting oil channels 8, it continuously comes into direct contact with the outer ring of the stator core 2, continuously carrying away the heat conducted from inside the stator core 2. During the flow of cooling oil through the gap between the stator winding 3 and the integrated injection-molded insulator 4, it continuously comes into direct contact with the stator winding 3, carrying away the heat conducted from the stator winding 3 and achieving uniform heat exchange throughout the stator. The cooling oil flowing through all the connecting oil channels 8 and the gap between the stator winding 3 and the integrated injection-molded insulator 4 eventually flows into the second winding end oil storage cavity 7, which is formed by the first thin-walled ring 504, the insulating cover plate 505, the insulating shell end ring 506, and the inner wall of the motor housing 1. It then submerges the other end of the stator winding 3 again and completes end heat exchange. The cooling oil carrying all the heat lost by the motor finally flows back to the external heat dissipation oil supply system through the oil outlet 10 to complete the cooling, thus achieving continuous heat dissipation of the motor in this cycle.

[0048] Throughout the entire cooling oil circulation process, the integrated injection-molded insulator 4 completely covers the inner wall of the stator slot, the slot opening, the outer ring, and the end faces of the stator core 2. This not only replaces traditional discrete insulating paper to achieve insulation protection between the winding and the stator core 2, ensuring the stability of the stator insulation performance, but also simultaneously seals the original fine gaps in the stator slot openings, reducing the path of cooling oil leakage from the slot openings to the rotor area. The gap between the integrated injection-molded insulator 4 and the inner wall of the motor housing 1 is filled with insulating sealant, further sealing the outer ring mating gap and reducing the probability of cooling oil leakage along the mating gap. The second thin-walled ring 507 located on the side of the oil storage cavity 6 at the end of the first winding overlaps with the metal thin-walled overlapping edge 501. The sealing ring mounting groove 502 forms a circumferential limit on the annular sealing ring 503, allowing the annular sealing ring 503 to stably fill the mating gap at the overlapping part, forming a radial sealing barrier and reducing the tendency of cooling oil in the oil storage cavity 6 at the end of the first winding to seep into the rotor cavity. The first thin-walled ring 504 located on the side of the oil storage chamber 7 at the end of the second winding is bonded and cured with insulating cover plate 505 and insulating shell end ring 506 through insulating sealant filled on the contact surface, forming an end face sealing barrier, which further prevents the cooling oil in the oil storage chamber 7 at the end of the second winding from diffusing into the stator-rotor air gap area; the sealing structures on both sides together form a two-way isolation protection, reducing the probability of cooling oil entering the stator-rotor air gap under various working conditions such as equipment tilting and shaking, reducing the oil churning loss generated when the rotor rotates at high speed, and at the same time weakening the possibility of oil contacting the rotor permanent magnet and intruding into the bearing area. The first thin-walled ring 504 and the second thin-walled ring 507, with an L-shaped longitudinal section and a mirror distribution, increase the contact surface with the integral injection-molded insulator 4, reducing the occurrence of root fracture. The thickness of the first thin-walled ring 504 and the second thin-walled ring 507 is 0.3mm, which is compatible with the reference air gap size of the stator and rotor. While achieving the sealing and isolation function, it reduces the impact on the equivalent electromagnetic air gap of the motor and ensures the stability of the motor's electromagnetic performance. The integral injection-molded insulator 4 and the two thin-walled rings are all integrally injection molded from glass fiber reinforced PPS, PEEK or LCP oil-resistant insulating composite materials. The insulating cover plate 505 is made of resin insulating material, which can reduce the swelling and cracking range when immersed in a high-temperature cooling oil environment for a long time, and maintain the long-term operational reliability of the sealing structure and insulation performance.

[0049] Example 2:

[0050] This embodiment is applicable to electric motors for small unmanned aerial vehicles. Compared to Embodiment 1, this embodiment omits the structures of the first thin-walled ring 504, the insulating shell end ring 506, and the second thin-walled ring 507, as detailed below:

[0051] See Figure 5 and Figure 6 In the above embodiments, the insulating sealing assembly 5 includes a thin-walled metal overlap edge 501, a sealing ring mounting groove 502, an annular sealing ring 503, and an insulating cover plate 505.

[0052] Specifically, a thin-walled metal overlap edge 501 is integrally formed on the inner side of the motor housing 1; an insulating cover plate 505 is bonded to one end of the motor housing 1 and the integral injection-molded insulator 4. The longitudinal section of the insulating cover plate 505 is "L"-shaped. Insulating sealant is filled between one end of the insulating cover plate 505, one end of the motor housing 1, and one end of the integral injection-molded insulator 4. One end of the insulating cover plate 505, the outer ring of the insulating cover plate 505, the inner ring of the motor housing 1, and one end of the integral injection-molded insulator 4 cooperate to form a second winding end oil storage cavity 7. The L-shaped insulating cover plate 505, together with the sealant, seals the end gaps, and the enclosed cavity accommodates cooling oil that immerses the winding end; the outer ring of the thin-walled metal overlap edge 501 and the integral injection-molded insulator 4... Both ends are provided with sealing ring mounting grooves 502, and both sealing ring mounting grooves 502 are connected to annular sealing rings 503. The integrated injection-molded insulator 4 is axially sealed with the motor housing 1 through one of the annular sealing rings 503, and the metal thin-walled overlapping edge 501 is radially sealed with the motor housing 1 through the other annular sealing ring 503. The double annular sealing rings 503 respectively achieve axial and radial bidirectional sealing and separate the stator oil circuit. The inner ring of the motor housing 1, the outer ring of the metal thin-walled overlapping edge 501 and the other end of the integrated injection-molded insulator 4 are fitted together to form the first winding end oil storage cavity 6. The structure is simplified to enclose the oil storage cavity, and the full-area oil immersion heat exchange of the winding end is achieved under the premise of lightweight.

[0053] The implementation principle of this embodiment is as follows: the cooling cycle logic is the same as that of Embodiment 1. The cooling oil flows in the integrated injection-molded insulator 4 and the connecting oil channel 8, fully immersing the stator core 2 and all stator windings 3, with no heat dissipation dead corners; only another sealing form is provided.

[0054] Both embodiments share a unified core innovative structure. The stator core 2 is fitted with an integrated injection-molded insulator 4 to form an insulating matrix. The integrated injection-molded insulator 4 itself constructs a stator-side sealing barrier, which, together with the insulating sealing structure, forms a completely independent stator oil-immersed cavity. This addresses the structural defects of existing oil-immersed motors, such as oil leakage through the air gap, complex sealing, and damage to electromagnetic performance. Embodiment 1 features a high-power manned aircraft motor with stronger pressure resistance and heat dissipation performance. Embodiment 2 is smaller in size and focuses on the lightweight and low-temperature stability requirements of small UAVs. Both embodiments can be flexibly selected according to motor power and operating environment.

[0055] Although embodiments of the present invention have been shown and described, these specific embodiments are merely illustrative of the invention and are not intended to limit it. The specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. After reading this specification, those skilled in the art may make modifications, substitutions, and variations to the embodiments as needed without departing from the principles and spirit of the invention, provided that such modifications, substitutions, and variations are within the scope of the claims of the present invention and are protected by patent law.

Claims

1. An integrated injection-molded stator oil-immersed cooling motor, comprising a motor housing (1), characterized in that: The motor housing (1) is provided with a stator core (2) inside. The stator core (2) is wrapped with a stator winding (3) in the stator slot. The inner wall, slot opening, outer ring and both ends of the stator slot of the stator core (2) are covered with an integral injection molded insulator (4). The integral injection molded insulator (4) has a through oil passage (8) at both ends. An insulation sealing assembly (5) is provided between the motor housing (1) and the integral injection molded insulator (4). The insulation sealing assembly (5) includes a metal thin-walled overlapping edge (501), a sealing ring mounting groove (502), an annular sealing ring (503), a first thin-walled ring (504), an insulation cover plate (505), an insulation housing end ring (506) and a second thin-walled ring (507). A first winding end oil storage cavity (6) and a second winding end oil storage cavity (7) are provided between the integral injection molded insulator (4) and the insulation sealing assembly (5).

2. The integrated injection-molded stator oil-immersed cooling motor according to claim 1, characterized in that: The inner side of the motor housing (1) is integrally formed with a thin-walled metal overlap edge (501). A sealing ring mounting groove (502) is provided on the outer ring of the thin-walled metal overlap edge (501). An annular sealing ring (503) is connected inside the sealing ring mounting groove (502). The two ends of the integral injection molded insulator (4) are respectively integrally formed with a first thin-walled ring (504) and a second thin-walled ring (507). The second thin-walled ring (507) cooperates with the thin-walled metal overlap edge (501) and the inner wall of the motor housing (1) to form a ring. The first winding end oil storage cavity (6) is formed by combining the first thin-walled ring (504) with an insulating cover plate (505) bonded to one end. An insulating shell end ring (506) is bonded to one end of the insulating cover plate (505) near the stator core (2). One end of the insulating shell end ring (506) is bonded to the inner wall of the motor housing (1). The first thin-walled ring (504), the insulating cover plate (505), the insulating shell end ring (506) and the inner wall of the motor housing (1) cooperate to form the second winding end oil storage cavity (7).

3. The integrated injection-molded stator oil-cooled motor according to claim 1, characterized in that: The outer ring of the motor housing (1) is provided with an oil inlet (9) and an oil outlet (10). The oil inlet (9) is connected to the oil storage chamber (6) at the end of the first winding, and the oil outlet (10) is connected to the oil storage chamber (7) at the end of the second winding. The two ends of the connecting oil passage (8) are connected to the oil storage chamber (6) at the end of the first winding and the oil storage chamber (7) at the end of the second winding, respectively.

4. The integrated injection-molded stator oil-cooled motor according to claim 2, characterized in that: The second thin-walled ring (507) is radially sealed to the metal thin-walled overlapping edge (501) through an annular sealing ring (503). The insulating cover plate (505) is filled with insulating sealant between the first thin-walled ring (504) and the insulating housing end ring (506). The gap between the integral injection-molded insulator (4) and the inner wall of the motor housing (1) is filled with insulating sealant.

5. The integrated injection-molded stator oil-immersed cooling motor according to claim 1, characterized in that: The integral injection-molded insulator (4), the first thin-walled ring (504), and the second thin-walled ring (507) are all integrally injection molded from glass fiber reinforced PPS, PEEK, or LCP oil-resistant insulating composite materials, and the insulating cover plate (505) is made of resin insulating material.

6. The integrated injection-molded stator oil-immersed cooling motor according to claim 1, characterized in that: Multiple connecting oil channels (8) are provided, and the multiple connecting oil channels (8) are distributed in a ring array.

7. The integrated injection-molded stator oil-cooled motor according to claim 2, characterized in that: The longitudinal sections of the first thin-walled ring (504) and the second thin-walled ring (507) are both "L" shaped, and the first thin-walled ring (504) and the second thin-walled ring (507) are mirror images of each other.

8. The integrated injection-molded stator oil-immersed cooling motor according to claim 1, characterized in that: The inner side of the motor housing (1) is integrally formed with a thin-walled metal overlap edge (501). An insulating cover plate (505) is bonded to one end of the motor housing (1) and the integral injection molded insulator (4). One end of the insulating cover plate (505), the outer ring of the insulating cover plate (505), the inner ring of the motor housing (1) and one end of the integral injection molded insulator (4) cooperate to form a second winding end oil storage cavity (7). The outer ring of the thin-walled metal overlap edge (501) and the other end of the integral injection molded insulator (4) are both provided with sealing ring mounting grooves (502). An annular sealing ring (503) is connected inside the two sealing ring mounting grooves (502). The inner ring of the motor housing (1), the outer ring of the thin-walled metal overlap edge (501) and the other end of the integral injection molded insulator (4) cooperate to form a first winding end oil storage cavity (6).

9. The integrated injection-molded stator oil-immersed cooling motor according to claim 8, characterized in that: The longitudinal section of the insulating cover plate (505) is "L" shaped, and the space between one end of the insulating cover plate (505), one end of the motor housing (1), and one end of the integral injection molded insulator (4) is filled with insulating sealant.

10. The integrated injection-molded stator oil-cooled motor according to claim 8, characterized in that: The integral injection-molded insulator (4) is axially sealed to the motor housing (1) through one of the annular sealing rings (503), and the metal thin-walled overlapping edge (501) is radially sealed to the motor housing (1) through the other annular sealing ring (503).

Images