Stator and method for processing thereof, electric machine

Abstract

The application belongs to the technical field of electric machines, and discloses a stator, a processing method thereof and an electric machine. The stator comprises a stator body and a plurality of coil windings, the plurality of coil windings are uniformly distributed in a ring shape, the stator body and the plurality of coil windings are integrally formed and closely arranged, the stator body is made of insulating magnetic powder, and the weight percentage of the magnetic powder in the insulating magnetic powder is greater than 80%. The stator sets the stator core to be integrally formed and closely arranged with the plurality of coil windings, thereby effectively reducing magnetic leakage and improving the performance of the electric machine. The stator body is made of insulating magnetic powder with a weight percentage of the magnetic powder greater than 80%, thereby effectively improving the magnetic permeability of the stator body and the output power of the electric machine. Moreover, the particle size of the magnetic powder is small, compared with the stator core formed by silicon steel sheets, the eddy current loss can be greatly reduced, and the performance of the electric machine is improved.

Description

Technical Field

[0001] This invention relates to the field of motor technology, and more particularly to stators and their processing methods, and motors. Background Technology

[0002] An electric motor, commonly known as a motor, is an electromagnetic device that converts or transmits electrical energy based on the law of electromagnetic induction. It is divided into electric motors and generators. Electric motors convert electrical energy into mechanical energy by generating torque, while generators convert mechanical energy into electrical energy. An electric motor consists of a rotating rotor and a stationary stator. An axial flux motor, also known as a disc motor or flat motor, is a special type of motor where the magnetic flux flows along the axial direction of the motor (i.e., along the motor's axis). Structurally, the rotor and stator of an axial flux motor are typically arranged in parallel discs, giving the motor a flat overall shape and saving space.

[0003] The stator of an axial / radial flux motor includes a stator core, stator windings, and other auxiliary structures. Typically, the stator core is made of laminated silicon steel sheets, which has relatively low dimensional accuracy. In order to ensure installation, the stator core is usually equipped with a magnetic yoke structure to reduce leakage flux and restrict the movement of the stator windings. However, this setting will bring considerable losses. At the same time, the thinner the silicon steel sheets, the lower the eddy current losses. However, if the silicon steel sheets are too thin, it will increase the processing difficulty and make it impossible to further reduce eddy current losses.

[0004] Therefore, a stator and its processing method, as well as an electric motor, are needed to solve the above problems. Summary of the Invention

[0005] The purpose of this invention is to provide a stator and its processing method, and a motor, which can integrate the stator core and winding coil into a whole, thereby reducing assembly steps, ensuring good dimensional accuracy, and ensuring that the stator core and winding coil are closely fitted, reducing magnetic leakage and improving heat dissipation performance. Furthermore, the use of insulating magnetic powder can reduce losses and improve motor performance.

[0006] To achieve this objective, the present invention adopts the following technical solution:

[0007] Stator, the stator comprising:

[0008] The stator body and several coil windings are arranged in a ring and are uniformly distributed. The stator body and several coil windings are integrally formed and tightly arranged. The stator body is made of insulating magnetic powder, and the weight percentage of magnetic powder in the insulating magnetic powder is greater than 80%.

[0009] As an optional technical solution, the insulating magnetic powder includes magnetic powder and an insulating layer surrounding the magnetic powder, wherein the thickness of the insulating layer is 0.05%-15% of the particle size of the magnetic powder.

[0010] As an optional technical solution, the particle size range of the magnetic powder is 1μm-150μm.

[0011] As an optional technical solution, the insulating magnetic powder further includes a binder, wherein the binder has a weight percentage of 0.1%-5%.

[0012] As an optional technical solution, the coil winding includes several parallel coil layers, and the shape of the coil layers includes a planar fan-shaped structure; and / or, at least one end of several of the coil windings is exposed outside the stator body along their own thickness direction.

[0013] The present invention also adopts the following technical solutions:

[0014] A one-step forming process for processing the stator described above includes the following steps:

[0015] S10A. Place several coil windings evenly in the first mold at a preset interval;

[0016] S20A. The stator body is formed by using a first forming device to form the insulating magnetic powder and closely distributing it to the plurality of coil windings.

[0017] As an optional technical solution, S20A specifically refers to:

[0018] The first forming device is a pressing device, which puts the insulating magnetic powder into the working groove, and uses the pressing device to apply a first preset pressure to the first mold and maintain it for a first preset time to form the stator;

[0019] Alternatively, the first molding device is a metal powder injection molding device, which injects the insulating magnetic powder into the working tank to form the stator.

[0020] The present invention also adopts the following technical solutions:

[0021] A step-by-step forming process is used to process the stator described above. The step-by-step forming process includes:

[0022] S10B. The insulating magnetic powder is placed into the second mold, and the second forming device is used to form the insulating magnetic powder into an intermediate transition body. The intermediate transition body includes a plurality of limiting parts, which are used to position the plurality of coil windings one by one.

[0023] S20B, Place the intermediate transition body into the third mold, and set a number of coil windings and a number of limiting parts in a one-to-one correspondence;

[0024] S30B, The third forming device is used to form the stator by the intermediate transition body and the plurality of coil windings.

[0025] As an optional technical solution, the intermediate transition body includes a first intermediate transition body and a plurality of second intermediate transition bodies. The first intermediate transition body has a plurality of receiving slots, which are used to accommodate a plurality of coil windings in a one-to-one correspondence, and the plurality of second intermediate transition bodies can be placed inside the plurality of coil windings in a one-to-one correspondence.

[0026] S20B is as follows: the first intermediate transition body is placed into the third mold, and a plurality of coil windings are correspondingly set with a plurality of limiting parts, and a plurality of second intermediate transition bodies are correspondingly placed inside the plurality of coil windings.

[0027] The present invention also adopts the following technical solutions:

[0028] The motor includes a housing, a rotating shaft, and a rotor. The motor also includes a stator as described above. The stator is installed inside the housing. The rotating shaft is rotatably disposed on the housing. The rotor is fixedly disposed on the rotating shaft. The stator and the rotor are spaced apart.

[0029] The beneficial effects of this invention are:

[0030] This invention discloses a stator comprising a stator body and a plurality of coil windings uniformly distributed in a ring. The stator body and the coil windings are integrally formed and tightly arranged. The stator body is made of insulating magnetic powder, with the magnetic powder comprising more than 80% by weight. This stator, by integrally forming and tightly arranged with the coil windings, effectively reduces magnetic leakage and improves motor performance. Furthermore, the absence of a yoke structure eliminates losses associated with it. The use of insulating magnetic powder comprising more than 80% by weight effectively increases the permeability of the stator body, thereby increasing the motor's output power. The smaller particle size of the magnetic powder, compared to a stator core formed from silicon steel sheets, significantly reduces eddy current losses and improves motor performance.

[0031] This invention also discloses a one-time molding process, which includes the following steps: S10A, placing a plurality of coil windings evenly in the working groove of a first mold at a preset interval; S20A, using a first molding device to form an insulating magnetic powder into a stator body that is tightly disposed with the plurality of coil windings. This one-time molding process has high processing efficiency, thereby effectively reducing production costs and improving the economic efficiency of the product.

[0032] This invention also discloses a step-by-step forming method for processing the aforementioned stator. The step-by-step forming method includes: S10B, placing a portion of insulating magnetic powder into a second mold, and using a second forming device to form a partial insulating magnetic powder into an intermediate transition body, the intermediate transition body being provided with a plurality of limiting parts, the plurality of limiting parts being used to position a plurality of coil windings one-to-one; S20B, placing the intermediate transition body into a third mold, and setting the plurality of coil windings one-to-one with the plurality of limiting parts; S30B, placing the remaining insulating magnetic powder into the third mold, and using a third forming device to form a stator body with the remaining insulating magnetic powder and the intermediate transition body, which is tightly set with the plurality of coil windings. This processing method adopts a step-by-step forming approach, firstly forming a portion of insulating magnetic powder into an intermediate transition body, the intermediate transition body being provided with a plurality of limiting parts, which can position a plurality of coil windings one-to-one, thereby ensuring the positional accuracy of the coil windings and improving the performance of the product.

[0033] This invention also discloses an electric motor, which includes a housing, a shaft, and a rotor. The motor also includes a stator as described above, with the stator installed inside the housing, the shaft rotatably mounted on the housing, and the rotor fixedly mounted on the shaft, with the stator and rotor spaced apart. This motor, by incorporating the aforementioned stator, can reduce magnetic leakage, thereby improving motor performance. Furthermore, the stator's integral molding structure eliminates losses in the magnetic yoke structure. The particle size of the insulating magnetic powder significantly reduces eddy current losses compared to silicon steel sheets, and over 80% of the magnetic powder ensures the permeability of the stator body, further enhancing motor performance. Attached Figure Description

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

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

[0036] Figure 3 This is a cross-sectional view of the motor according to Embodiment 1 of the present invention;

[0037] Figure 4 This is a schematic diagram of the stator structure of Embodiment 2 of the present invention;

[0038] Figure 5 This is a cross-sectional view of the stator in Embodiment 2 of the present invention;

[0039] Figure 6 This is a flowchart of the one-time molding process of Embodiment 3 of the present invention;

[0040] Figure 7 This is a flowchart of the one-time molding process of Embodiment 4 of the present invention;

[0041] Figure 8 This is a schematic diagram of the intermediate transition body in Embodiment 5 of the present invention;

[0042] Figure 9 This is a cross-sectional view of the intermediate transition body in Embodiment 5 of the present invention;

[0043] Figure 10 This is a schematic diagram of the structure of the first intermediate transition body in Embodiment 8 of the present invention;

[0044] Figure 11 This is a cross-sectional view of the first intermediate transition body in Embodiment 8 of the present invention;

[0045] Figure 12 This is a schematic diagram of the structure of the coil winding placed in the receiving groove of the first intermediate transition body in Embodiment 8 of the present invention;

[0046] Figure 13 This is a schematic diagram of the structure of the second intermediate transition body in Embodiments 8 and 9 of the present invention;

[0047] Figure 14 This is a schematic diagram of the structure of the first intermediate transition body in Embodiment 9 of the present invention;

[0048] Figure 15 This is a cross-sectional view of the first intermediate transition body in Embodiment 9 of the present invention;

[0049] Figure 16 This is a flowchart of the step-by-step molding process of Embodiments 5 to 9 of the present invention.

[0050] In the picture:

[0051] 1. Stator; 2. Housing; 3. Shaft; 4. Rotor;

[0052] 10. Stator body; 11. Intermediate transition body; 111. Limiting ring groove; 12. First intermediate transition body; 121. Receiving groove; 13. Second intermediate transition body;

[0053] 20. Coil winding. Detailed Implementation

[0054] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, and not all of the structures.

[0055] In the description of this invention, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0056] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0057] In the description of this embodiment, the terms "upper," "lower," "right," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention. In addition, the terms "first" and "second" are used only for distinction in description and have no special meaning.

[0058] Example 1

[0059] like Figures 1 to 2 As shown, this embodiment provides a stator 1, which includes a stator body 10 and a plurality of coil windings 20. The plurality of coil windings 20 are evenly distributed in a ring. The stator body 10 and the plurality of coil windings 20 are integrally formed and tightly arranged. The stator body 10 is made of insulating magnetic powder, and the weight percentage of magnetic powder in the insulating magnetic powder is greater than 80%.

[0060] Specifically, in this embodiment, the stator 1 has a stator core integrally formed and tightly arranged with several coil windings 20, thereby effectively reducing magnetic leakage and improving motor performance. Furthermore, the integral and tight arrangement of the coil windings 20 with the stator body 10 also increases the heat dissipation performance of the coil windings 20, thereby improving the heat dissipation of the motor equipped with the stator 1 and extending its service life. The stator body 10 is made of insulating magnetic powder with a magnetic powder weight percentage greater than 80%, which effectively improves the permeability of the stator body 10, thereby increasing the output power of the motor. Moreover, the smaller particle size of the magnetic powder, compared to the stator core formed from silicon steel sheets, significantly reduces eddy current losses and improves motor performance.

[0061] Specifically, in this embodiment, the insulating magnetic powder is magnetic only when the coil winding 20 is energized, and has good insulation properties. Therefore, there is no magnetic leakage and the magnetic circuit impedance is small, and the permeability is high. Thus, the number of coil turns can be greatly reduced, thereby reducing the amount of raw materials used. It is also beneficial to reduce the size of the product, which is conducive to the miniaturization design of the product and enhances its competitiveness.

[0062] Specifically, in this embodiment, the insulating magnetic powder is a soft magnetic composite material (SMC), which has excellent magnetic properties, including high magnetic permeability, strong magnetic saturation induction, and low magnetic hysteresis loss. It can improve the power conversion efficiency and has stable magnetic properties, which are not easily affected by environmental factors such as temperature and humidity, and has good stability and reliability.

[0063] Furthermore, the insulating magnetic powder includes magnetic powder and an insulating layer surrounding the magnetic powder, and the thickness of the insulating layer is 0.05%-15% of the particle size of the magnetic powder. Specifically, in this embodiment, the insulating layer ensures current isolation, thereby ensuring the performance of the coil winding 20, preventing current leakage to the outside and causing short circuits or electric shock hazards, greatly improving the electrical safety of the motor, protecting operators and equipment from electrical faults; at the same time, it enhances the operational stability of the motor.

[0064] Specifically, in this embodiment, the insulating layer can be an organic insulating layer or an inorganic insulating layer, and there is no limitation on this.

[0065] Specifically, in this embodiment, the insulating layer is coated onto the outer periphery of the magnetic powder by a coating process, and the coating process is existing technology, which will not be described in detail here.

[0066] Furthermore, the particle size of the magnetic powder ranges from 1μm to 150μm. In this embodiment, since eddy current loss is caused by the induced electromotive force generated within the magnetic material in an alternating magnetic field, leading to eddy currents, and these eddy currents generate Joule heat as they flow within the material, thus converting electromagnetic wave energy into heat energy, the smaller the particle size of the magnetic powder, the lower the eddy current loss. The particle size range of the magnetic powder (1μm-150μm) significantly reduces eddy current loss compared to the thickness of silicon steel sheets (0.2mm-1mm), thereby improving motor performance.

[0067] Specifically, in this embodiment, the magnetic powder can be a narrow range of particle size distribution, or it can be a wide range of particle size distribution with multiple particle sizes coexisting. No specific limitation is made here.

[0068] Furthermore, the insulating magnetic powder also includes an adhesive, with the adhesive accounting for 0.1%-5% by weight. Specifically, in this embodiment, the adhesive is an organic glue, which ensures that the insulating magnetic powder has a good molding effect while ensuring the structural stability of the stator body 10.

[0069] Specifically, in this embodiment, the higher the content of adhesive, the higher the structural strength of the stator body 10 after molding. The weight percentage of adhesive can be 5%, 4.5%, 4% or other values, and there is no limitation here.

[0070] Furthermore, the coil winding 20 includes several parallel and sequentially connected coil layers, and the structure of the coil layers includes a planar fan-shaped structure; and / or, at least one end of each coil winding 20 is exposed outside the stator body 10 along its thickness direction. Specifically, in this embodiment, the stator body 10 has a high content of magnetic powder, which only conducts magnetism when energized, thus exhibiting no magnetic leakage and low magnetic circuit impedance, and high permeability. Therefore, the number of coil turns can be significantly reduced, reducing the amount of raw materials used. Compared with traditional brushless permanent magnet motors, under the same power conditions, the coil winding 20 in this embodiment has fewer turns, resulting in higher effective output of the motor and facilitating miniaturization design of the product. Specifically, in this embodiment, the coil windings 20 are connected according to actual usage needs, and the connection method can be series or parallel, without specific limitations.

[0071] In this embodiment, one end of several coil windings 20 along their thickness direction is exposed outside the stator body 10, which makes the stator 1 suitable for a single rotor 4 motor. The one end exposed outside the stator body 10 is spaced apart from the rotor 4, thereby reducing the air gap between the stator 1 and the rotor 4 and improving the performance of the motor.

[0072] Specifically, in this embodiment, the coil winding 20 includes one, two, or three coil layers. The number of coil layers can be set according to actual use and is not limited here.

[0073] Specifically, in this embodiment, the structure of the coil layer can be configured according to actual use, and can be a planar sector or a similar sector structure, without limitation.

[0074] Furthermore, the magnetic powder includes one or more of the following: pure iron powder, low-carbon steel powder, pure nickel powder, iron-silicon alloy powder, iron-aluminum alloy powder, iron-silicon-aluminum alloy powder, nickel-iron alloy powder, and iron-cobalt alloy powder. Specifically, in this embodiment, the types and contents of the powders included in the magnetic powder can be specifically set according to actual use, and will not be elaborated here.

[0075] like Figure 3 As shown, this embodiment also provides a motor, which includes a housing 2, a rotating shaft 3, and a rotor 4. The motor also includes the aforementioned stator 1, which is installed inside the housing 2. The rotating shaft 3 is rotatably mounted on the housing 2, and the rotor 4 is fixedly mounted on the rotating shaft 3, with the stator 1 and rotor 4 spaced apart. This motor, by incorporating the aforementioned stator 1, can reduce magnetic leakage, thereby improving motor performance. Furthermore, the stator 1 is a one-piece molded structure, which eliminates losses in the magnetic yoke structure. The particle size of the insulating magnetic powder significantly reduces eddy current losses compared to silicon steel sheets, and over 80% of the magnetic powder ensures the permeability of the stator body 10, thus improving motor performance.

[0076] Specifically, in this embodiment, the motor is a single-rotor 4-motor. The stator 1 is disposed on one side of the housing 2, the shaft 3 is rotatably disposed on the housing 2, and the rotor 4 is fixedly disposed on the shaft 3. The rotor 4 and the stator 1 are spaced apart. One end of the coil winding 20 along its own height direction is exposed outside the stator body 10, and the exposed side of the coil winding 20 is closer to the rotor 4 than the other side, which can reduce the air gap between the stator 1 and the rotor 4, thereby facilitating the miniaturization design of the motor.

[0077] Specifically, this embodiment uses the stator 1 of an axial flux motor (disc motor) as an example for explanation. In other embodiments, the stator 1 of a radial flux motor can also be the structure described above, in which the stator body 10 made of insulating magnetic powder and several coil windings 20 are integrally formed and closely arranged. No specific limitation is made here.

[0078] Example 2

[0079] This embodiment provides a stator 1; please refer to [link / reference]. Figure 4 and Figure 5The stator 1 in this embodiment differs from the stator 1 in embodiment 1 in that the coil windings 20 of the stator 1 in this embodiment are exposed at both ends along their height direction to the stator body 10. This stator 1 is suitable for motors with dual rotors 4, which can reduce the air gap between the two rotors 4 and the stator 1, thereby improving the performance of the motor.

[0080] This embodiment also provides an electric motor, which includes a housing 2, a rotating shaft 3, and two rotors 4. The motor also includes a stator 1 as described above. The stator 1 is disposed inside the housing 2, between the two rotors 4, and the two rotors 4 are spaced apart from the stator 1. Both ends of the stator 1 along its height are exposed outside the stator body 10, which can eliminate the loss of the magnetic yoke structure and reduce the magnetic field passing through the air gap between the stator 1 and the rotors 4, thereby increasing the air gap magnetic density. This is beneficial for improving the miniaturization design of the motor and improving the performance of the motor. At the same time, the particle size of the insulating magnetic powder can greatly reduce eddy current losses compared with silicon steel sheets, and more than 80% of the magnetic powder can ensure the magnetic permeability of the stator body 10, thereby improving the performance of the motor.

[0081] It is also understandable that, Figure 4 and Figure 5 In the schematic diagram, the stator 1 includes only one set of coil windings 20. The set of coil windings 20 in the stator 1 corresponds to two rotors 4. When both ends of the coil windings 20 of the stator 1 are exposed outside the stator body 10 along its own height direction and it is applied to a dual-rotor single-stator or multi-rotor multi-stator motor, two sets of coil windings 20 can be set in the process of integral molding. The two sets of coil windings 20 are set in parallel.

[0082] Example 3

[0083] like Figure 6 As shown, this embodiment provides a one-time molding processing method, which can be used to process the stator 1 in embodiment 2. The one-time molding processing method includes the following steps.

[0084] S10A. Place several coil windings 20 evenly in the first mold according to a preset interval.

[0085] Furthermore, in this embodiment, the stator 1 can be formed by compression molding or metal powder injection molding, and the first mold for compression molding and metal powder injection molding is different.

[0086] Specifically, in this embodiment, when compression molding is used, the first mold is a mold with a first working groove. When implementing the above-mentioned one-time molding process, a number of coil windings 20 are evenly placed in the first working groove of the first mold according to a preset interval.

[0087] Specifically, in this embodiment, when metal powder injection molding is used, the first mold is a mold with a first working cavity. First, the mold needs to be separated, and then several coil windings 20 are evenly placed in the receiving cavity on one side of the first mold according to a preset interval, and then the mold is closed.

[0088] Optionally, in this embodiment, the compression molding can be either room temperature compression molding or hot pressing molding. Both room temperature compression molding and hot pressing molding are existing technologies and will not be described in detail here.

[0089] S20A, using a first forming device, insulating magnetic powder is formed into a stator body 10 that is closely disposed with several coil windings 20, so as to form a stator 1.

[0090] Specifically, in this embodiment, when pressing is used, the first forming device is a pressing device. After placing several coil windings 20 evenly in the working groove of the first mold at a preset interval, insulating magnetic powder is placed in the working groove, and the pressing device is used to apply a first preset pressure to the first mold and maintain it for a first preset time to form the stator 1.

[0091] Optionally, the first preset pressure and the first preset time can be set according to actual use, and there are no restrictions here.

[0092] Specifically, in this embodiment, when metal powder injection molding is used, the first molding device is a metal powder injection molding device, which includes an injection machine. After several coil windings 20 are evenly placed in the first working cavity of the first mold at a preset interval, the insulating powder is heated into a rheological plastic material in the barrel of the injection machine and injected into the working groove under appropriate injection pressure to form a blank. Then the blank can be sintered to form the stator 1.

[0093] The stator 1 processed in this way can ensure that both ends of the coil winding 20 along the height direction can be exposed outside the stator body 10, thus making it suitable for motors with a single stator 1 and dual rotors 4 or a multi-disc structure in which the stator 1 and rotor 4 are axially spaced along the shaft 3. This can reduce the air gap between the rotor 4 and the stator 1, thereby effectively increasing the air gap magnetic density and improving the performance of motors equipped with the stator 1.

[0094] Example 4

[0095] like Figure 7 As shown, this embodiment provides a one-time forming processing method for stator 1, which can be used to process stator 1 in embodiment 1. The difference between the one-time forming processing method in this embodiment and the one-time forming processing method in embodiment 2 is that: when using compression molding to manufacture stator 1, the following steps are included before performing S10A.

[0096] S9A. A layer of insulating magnetic powder is evenly laid in the first mold.

[0097] Specifically, in this embodiment, performing S10A after S9A enables the bottom of the formed stator 1 to have a layer of insulating magnetic powder, which is more suitable for single-rotor single-stator or single-rotor double-stator motors, thereby facilitating the connection between the stator 1 and the housing 2 and improving the operational stability of the motor equipped with the stator 1.

[0098] It should be noted that in Example 3, the stator 1 in Example 2 was prepared by pressing the insulating magnetic powder and the coil winding 20 together in a single filling process, and in Example 4, the stator 1 in Example 1 was prepared by pressing the insulating magnetic powder and the coil winding 20 together in a double filling process. However, it is understood that the stator 1 in Example 2 can still be prepared by pressing the insulating magnetic powder and the coil winding 20 together in a single filling process, and the stator 1 in Example 1 can also be prepared by pressing the insulating magnetic powder and the coil winding 20 together in a double filling process.

[0099] Example 5

[0100] like Figure 16 As shown, this embodiment provides a step-by-step forming process method, which can be applied to the processing of stator 1 in embodiment 1. It can improve the positional accuracy of coil winding 20, thereby improving the performance of the product.

[0101] Specifically, the step-by-step forming process in this embodiment includes the following steps:

[0102] S10B. The insulating magnetic powder is placed into the second mold, and the second molding device is used to form the insulating magnetic powder into an intermediate transition body 11. The intermediate transition body 11 includes several limiting parts, which are used to position several coil windings 20 in a one-to-one correspondence.

[0103] Furthermore, such as Figure 8 and Figure 9 As shown, in this embodiment, the intermediate transition body 11 includes a main body and a limiting part consisting of several limiting ring grooves 111 disposed on the main body. The several limiting ring grooves 111 are evenly distributed in a ring on the main body, and the several limiting ring grooves 111 are used to accommodate several coil windings 20 in a corresponding manner.

[0104] Furthermore, in this embodiment, the intermediate transition body 11 can be formed by compression molding or metal powder injection molding, and the second mold for compression molding and metal powder injection molding is different.

[0105] Specifically, in this embodiment, when pressing is used, the second mold is a mold with a second working groove. In step S10B, insulating magnetic powder is placed into the second working groove of the second mold. The second forming device is a pressing device. The pressing device includes a pressing head with a plurality of convex ring structures corresponding to a plurality of coil windings 20. The pressing device drives the pressing head to apply pressure to the second working groove, thereby forming the intermediate transition body 11.

[0106] Preferably, in this embodiment, the pressure value P1 applied by the pressing device to the insulating magnetic powder through the pressing head is 200MPa-1500MPa, and the holding time can be specifically set according to actual use, without specific limitations.

[0107] Optionally, in this embodiment, when metal powder injection molding is used, the second mold is a mold with a second working cavity. The metal powder injection molding apparatus includes an injection machine. The insulating powder is heated into a rheological plastic material in the barrel of the injection machine and injected into the second working cavity under appropriate injection pressure, thereby forming the above-mentioned intermediate transition body 11.

[0108] S20B, Place the intermediate transition body 11 into the third mold, and set several coil windings 20 and several limiting parts in a corresponding manner.

[0109] Specifically, in this embodiment, several coil windings 20 are placed one-to-one in several limiting ring grooves 111 of the main body. The limiting ring grooves 111 can position the coil windings 20, thereby ensuring the positional accuracy of the coil windings 20 and improving the performance of the stator 1.

[0110] S30B, using a third forming device, the intermediate transition body 11 and several coil windings 20 form the stator 1.

[0111] Specifically, in this embodiment, the third forming device is a pressing device. The pressing device can apply a certain pressure to the intermediate transition body 11 and several coil windings 20, so that the intermediate transition body 11 and several coil windings 20 can be formed into a whole and tightly arranged, thereby ensuring the structural strength and performance of the stator 1.

[0112] Specifically, in this embodiment, the pressure value P2 applied by the pressing device to the intermediate transition body 11 and several coil windings 20 is 500MPa-2100MPa, and preferably, P2>P1, so as to improve the forming effect of the stator 1. At the same time, the holding time can be specifically set according to actual use, and no specific limitation is made here.

[0113] The stator 1 processed in this way has only one end of the coil winding 20 exposed outside the stator body 10, which is more suitable for use in single-rotor single-stator motors or single-rotor double-stator motors. It can facilitate the connection between the stator 1 and the housing 2 and improve the stability of the motor with the stator 1.

[0114] Example 6

[0115] like Figure 16 As shown, this embodiment discloses a step-by-step forming process for stator 1, which can be used for the processing of stator 1 in embodiment 2. It can also improve the positional accuracy of coil winding 20, thereby improving the performance of the product. The difference between the step-by-step forming process in this embodiment and the step-by-step forming process in embodiment 5 is that the specific structure of the intermediate transition body 11 is different.

[0116] Specifically, the step-by-step forming process in this embodiment includes the following steps:

[0117] S10B. The insulating magnetic powder is placed into the second mold, and the second molding device is used to form the insulating magnetic powder into an intermediate transition body 11. The intermediate transition body 11 includes several limiting parts, which are used to position several coil windings 20 in a one-to-one correspondence.

[0118] Specifically, in this embodiment, the intermediate transition body 11 includes several limiting blocks, which can be accommodated one-to-one in the inner cavity of several coil windings 20, thereby positioning the several coil windings 20. In this embodiment, the limiting blocks are the aforementioned limiting parts.

[0119] Furthermore, in this embodiment, the limiting block can be formed by compression molding or metal powder injection molding, and the second mold for compression molding and metal powder injection molding is different.

[0120] Specifically, in this embodiment, when compression molding is used, the second mold is a mold with a second working groove. In step S10B above, insulating magnetic powder is placed into the second working groove of the second mold. The second molding device is a pressing device. The pressing device is provided with a pressure head with a groove corresponding to the limiting block. The pressing device drives the pressure head to apply pressure to the second working groove, thereby forming the limiting block. The above steps are repeated multiple times to make several limiting blocks, thereby forming the intermediate transition body 11.

[0121] Preferably, in this embodiment, the pressure value P1 applied by the pressing device to the insulating magnetic powder through the pressing head is 200MPa-1500MPa, and the holding time can be specifically set according to actual use, without specific limitations.

[0122] Optionally, in this embodiment, when metal powder injection molding is used, the second mold is a mold with a second working cavity. The metal powder injection molding device includes an injection machine. The insulating powder is heated into a rheological plastic material in the barrel of the injection machine and injected into the second working cavity under appropriate injection pressure to form the above-mentioned limiting block. The above steps are repeated multiple times to make several limiting blocks, thereby forming the intermediate transition body 11.

[0123] S20B, Place the intermediate transition body 11 into the third mold, and set several coil windings 20 and several limiting parts in a corresponding manner.

[0124] Specifically, in this embodiment, several limiting blocks are placed in the third mold, and several coil windings 20 are respectively fitted onto the periphery of several limiting blocks, thereby enabling the positioning of several coil windings 20, thereby ensuring the positional accuracy of the coil windings 20, and thus improving the performance of the stator 1.

[0125] S30B, using a third forming device, the intermediate transition body 11 and several coil windings 20 form the stator 1.

[0126] Specifically, in this embodiment, before molding, insulating magnetic powder needs to be placed into the third mold to replenish the remaining insulating magnetic powder for forming the stator body 10.

[0127] Furthermore, the third forming device is a pressing device. The pressing device can apply a certain pressure to the intermediate transition body 11 formed by several limiting blocks, several coil windings 20 and supplementary insulating magnetic powder, so that the intermediate transition body 11 formed by several limiting blocks, several coil windings 20 and supplementary insulating magnetic powder can be formed into a whole and tightly set, thereby ensuring the structural strength and performance of the stator 1.

[0128] Specifically, in this embodiment, the pressure value P2 applied by the pressing device to the intermediate transition body 11 formed by several limiting blocks, several coil windings 20 and supplemented insulating magnetic powder is 500MPa-2100MPa, and preferably, P2>P1, so as to improve the forming effect of stator 1. At the same time, the holding time can be specifically set according to actual use, and no specific limitation is made here.

[0129] The stator 1 manufactured by the above-mentioned step-by-step forming process can ensure that both ends of the coil winding 20 along the height direction can be exposed outside the stator body 10, thus making it suitable for dual-rotor single-stator motors or multi-rotor multi-stator motors. It can reduce the air gap between the rotor 4 and the stator 1, thereby effectively increasing the air gap magnetic density and improving the performance of motors equipped with the above-mentioned stator 1.

[0130] Example 7

[0131] like Figure 16 As shown, this embodiment discloses a step-by-step forming process for stator 1, which is used for the processing of stator 1 in embodiment 1. It can also improve the positional accuracy of coil winding 20, thereby improving the performance of the product. The step-by-step forming process in this embodiment differs from the step-by-step forming process in embodiment 6 in that the following content is added before S20B: S19B, a layer of insulating magnetic powder is evenly laid in the third mold.

[0132] Specifically, the step-by-step forming process in this embodiment includes the following steps:

[0133] S10B. The insulating magnetic powder is placed into the second mold, and the second molding device is used to form the insulating magnetic powder into an intermediate transition body 11. The intermediate transition body 11 includes several limiting parts, which are used to position several coil windings 20 in a one-to-one correspondence.

[0134] Specifically, in this embodiment, the intermediate transition body 11 includes several limiting blocks, which can be accommodated one-to-one in the inner cavity of several coil windings 20, thereby positioning the several coil windings 20. In this embodiment, the limiting blocks are the aforementioned limiting parts.

[0135] Furthermore, in this embodiment, the limiting block can be formed by compression molding or metal powder injection molding, and the second mold for compression molding and metal powder injection molding is different.

[0136] Specifically, in this embodiment, when compression molding is used, the second mold is a mold with a second working groove. In step S10B above, insulating magnetic powder is placed into the second working groove of the second mold. The second molding device is a pressing device. The pressing device is provided with a pressure head with a groove corresponding to the limiting block. The pressing device drives the pressure head to apply pressure to the second working groove, thereby forming the limiting block. The above steps are repeated multiple times to make several limiting blocks, thereby forming the intermediate transition body 11.

[0137] Preferably, in this embodiment, the pressure value P1 applied by the pressing device to the insulating magnetic powder through the pressing head is 200MPa-1500MPa, and the holding time can be specifically set according to actual use, without specific limitations.

[0138] Optionally, in this embodiment, when metal powder injection molding is used, the second mold is a mold with a second working cavity. The metal powder injection molding device includes an injection machine. The insulating powder is heated into a rheological plastic material in the barrel of the injection machine and injected into the second working cavity under appropriate injection pressure to form the above-mentioned limiting block. The above steps are repeated multiple times to make several limiting blocks, thereby forming the intermediate transition body 11.

[0139] S19B, A layer of insulating magnetic powder is evenly laid in the third mold.

[0140] Specifically, in this embodiment, a layer of insulating magnetic powder is evenly laid in the third mold before molding, which allows the coil winding 20 of the stator 1 to be exposed outside the stator body 10 along only one side of its own thickness. This is more suitable for single rotor single stator motors or single rotor double stator motors, and facilitates the connection between the stator 1 and the housing 2, thereby improving the stability of the motor equipped with the stator 1.

[0141] S20B, Place the intermediate transition body 11 into the third mold, and set several coil windings 20 and several limiting parts in a corresponding manner.

[0142] Specifically, in this embodiment, several limiting blocks are placed in the third mold, and several coil windings 20 are respectively fitted onto the periphery of several limiting blocks, thereby enabling the positioning of several coil windings 20, thereby ensuring the positional accuracy of the coil windings 20, and thus improving the performance of the stator 1.

[0143] S30B, using a third forming device, the intermediate transition body 11 and several coil windings 20 form the stator 1.

[0144] Specifically, in this embodiment, before molding, some additional insulating magnetic powder needs to be placed into the third mold to supplement the remaining insulating magnetic powder for forming the stator body 10.

[0145] Furthermore, the third forming device is a pressing device. The pressing device can apply a certain pressure to the intermediate transition body 11 formed by several limiting blocks, several coil windings 20 and supplementary insulating magnetic powder, so that the intermediate transition body 11 formed by several limiting blocks, several coil windings 20 and supplementary insulating magnetic powder can be formed into a whole and tightly set, thereby ensuring the structural strength and performance of the stator 1.

[0146] Specifically, in this embodiment, the pressure value P2 applied by the pressing device to the intermediate transition body 11 formed by several limiting blocks, several coil windings 20 and supplemented insulating magnetic powder is 500MPa-2100MPa, and preferably, P2>P1, so as to improve the forming effect of stator 1. At the same time, the holding time can be specifically set according to actual use, and no specific limitation is made here.

[0147] The stator 1 processed in this way has only one end of the coil winding 20 exposed outside the stator body 10, which is more suitable for use in single-rotor single-stator motors or single-rotor double-stator motors. It facilitates the connection between the stator 1 and the housing 2 and improves the stability of the motor equipped with the stator 1.

[0148] Example 8

[0149] like Figure 16 As shown, this embodiment discloses a step-by-step forming process for stator 1, which is used for the processing of stator 1 in embodiment 2. It can also improve the positional accuracy of coil winding 20, thereby improving the performance of the product. The step-by-step forming process in this embodiment differs from the step-by-step forming process in embodiment 5 in that the intermediate transition body 11 includes a first intermediate transition body 12 and several second intermediate transition bodies 13. S20B is: the first intermediate transition body 12 is placed into the third mold, and several coil windings 20 are correspondingly set with several limiting parts, and several second intermediate transition bodies 13 are placed inside several coil windings 20.

[0150] like Figure 10 and Figure 11 As shown, specifically in this embodiment, the first intermediate transition body 12 has a plurality of receiving slots 121, which are used to accommodate a plurality of coil windings 20 in a one-to-one correspondence, and a plurality of second intermediate transition bodies 13 can be placed inside the plurality of coil windings 20 in a one-to-one correspondence. The first intermediate transition body 12 and the second intermediate transition body 13 configured in this way together form a limiting part, which can position the coil windings 20, improve the positional accuracy of the coil windings 20, and thus improve the performance of the stator 1.

[0151] Specifically, in this embodiment, the receiving slot 121 is a through slot, which allows both ends of the coil winding 20 along the height direction to be exposed outside the stator body 10, thus making it suitable for a motor with a single stator 1 and dual rotors 4. This can reduce the air gap between the rotor 4 and the stator 1, thereby effectively increasing the air gap magnetic density and improving the performance of the motor equipped with the stator 1.

[0152] Specifically, in this embodiment, S10B is used to form the intermediate transition body 11. Specifically, S10B includes S101B and S102B, wherein S101B is used to process the first intermediate transition body 12 and S102B is used to process the second intermediate transition body 13.

[0153] S101B. The insulating magnetic powder is placed into the fourth mold, and the fourth molding device is used to form the insulating magnetic powder into the first intermediate transition body 12.

[0154] Furthermore, in this embodiment, the first intermediate transition body 12 can be formed by compression molding or metal powder injection molding, and the fourth mold for compression molding and metal powder injection molding are different.

[0155] Specifically, when compression molding is used, the fourth mold is a mold with a fourth working groove. In step S101B above, insulating magnetic powder is placed into the fourth working groove of the fourth mold. The fourth molding device is a pressing device. The pressing device includes a pressing head with a plurality of protrusions corresponding to a plurality of receiving cavities. The pressing device drives the pressing head to apply pressure to the fourth working groove, thereby forming the first intermediate transition body 12 mentioned above.

[0156] Preferably, in this embodiment, the pressure value P1 applied by the pressing device to the insulating magnetic powder through the pressing head is 200MPa-1500MPa, and the holding time can be specifically set according to actual use, without specific limitations.

[0157] Optionally, in this embodiment, when metal powder injection molding is used, the fourth mold is a mold with a fourth working cavity. The metal powder injection molding apparatus includes an injection machine. The insulating powder is heated in the barrel of the injection machine into a plastic material with rheological properties and injected into the fourth working cavity under appropriate injection pressure to form the first intermediate transition body 12 mentioned above.

[0158] S102B, The insulating magnetic powder is placed into the fifth mold, and the fifth molding device is used to form the insulating magnetic powder into the second intermediate transition body 13.

[0159] Furthermore, such as Figure 13 As shown, in this embodiment, the second intermediate transition body 13 can be formed by compression molding or metal powder injection molding. The fourth mold for compression molding and metal powder injection molding is different, and the forming process of the second intermediate transition body 13 is similar to that of the first intermediate transition body 12, which will not be described in detail here.

[0160] The stator 1 manufactured by the above-mentioned step-by-step forming process can ensure that both ends of the coil winding 20 along the height direction can be exposed outside the stator body 10, thus making it suitable for dual-rotor single-stator motors or multi-rotor multi-stator motors. It can reduce the air gap between the rotor 4 and the stator 1, thereby effectively increasing the air gap magnetic density and improving the performance of motors equipped with the above-mentioned stator 1.

[0161] Example 9

[0162] like Figure 16 As shown, this embodiment provides a step-by-step forming process for stator 1, which is used for the processing of stator 1 in embodiment 1. It can also improve the positional accuracy of coil winding 20, thereby improving the performance of the product. The step-by-step forming process in this embodiment differs from the step-by-step forming process in embodiment 6 in that the specific structure of the first intermediate transition body 12 is different.

[0163] Specifically, such as Figure 14 and Figure 15 As shown, in this embodiment, the first intermediate transition body 12 has several limiting grooves and several receiving grooves 121 for correspondingly accommodating several coil windings 20, and the limiting grooves have only one opening communicating with the outside. This first intermediate transition body 12 and the second intermediate transition body 13 together form a limiting part, which can position the coil windings 20, thereby improving the positional accuracy of the coil windings 20 and thus improving the performance of the stator 1.

[0164] Specifically, in this embodiment, S10B is used to form the intermediate transition body 11. Specifically, S10B includes S101B and S102B in embodiment 8, and the following steps are included before S101B.

[0165] S100B, A layer of insulating magnetic powder is evenly laid in the sixth mold.

[0166] Specifically, in this embodiment, a layer of insulating magnetic powder is uniformly laid in the sixth mold. The thickness of the insulating magnetic powder is set according to the actual use, which will not be elaborated here.

[0167] Specifically, in this embodiment, performing S101B after S100B enables the bottom of the first intermediate transition body 12 to have a layer of insulating magnetic powder, thereby ensuring that only one end of the formed stator 1 is exposed outside the stator body 10 along its height direction. This makes the stator 1 more suitable for single-rotor single-stator motors or single-rotor double-stator motors, facilitating the connection between the stator 1 and the housing 2, and improving the stability of the motor equipped with the stator 1.

[0168] In the above embodiments, the stator 1 is formed by molding the coil winding 20 and filling it with insulating magnetic powder in one step; or by first laying the insulating magnetic powder, placing the coil winding 20, and then molding it with the insulating magnetic powder; or by first forming an intermediate transition body 11 to limit the coil winding 20, and then molding it with the insulating magnetic powder; or by first forming an intermediate transition body 11 to limit the coil winding 20, and then molding it with the intermediate transition body 11 directly with the coil winding 20 to form the stator 1, so that the stator body 10 and several coil windings 20 are integrally formed and tightly arranged.

[0169] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art will be able to make various obvious changes, readjustments, and substitutions without departing from the scope of protection of the present invention. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A stator, characterized in that, The stator (1) includes: The stator body (10) and several coil windings (20) are arranged in a ring and are uniformly distributed. The stator body (10) and several coil windings (20) are integrally formed and tightly arranged. The stator body (10) is made of insulating magnetic powder, and the weight percentage of magnetic powder in the insulating magnetic powder is greater than 80%.

2. The stator according to claim 1, characterized in that, The insulating magnetic powder includes magnetic powder and an insulating layer surrounding the magnetic powder, wherein the thickness of the insulating layer is 0.05%-15% of the particle size of the magnetic powder.

3. The stator according to claim 2, characterized in that, The particle size range of the magnetic powder is 1μm-150μm.

4. The stator according to claim 2, characterized in that, The insulating magnetic powder also includes a binder, wherein the binder has a weight percentage of 0.1%-5%.

5. The stator according to claim 1, characterized in that, The coil winding (20) includes a plurality of parallel coil layers, and the shape of the coil layers includes a planar fan-shaped structure; and / or, at least one end of each of the coil windings (20) is exposed outside the stator body (10) along its own thickness direction.

6. A one-step forming method for processing the stator according to any one of claims 1-5, characterized in that, The one-time molding process includes the following steps: S10A. Place several coil windings (20) evenly in the first mold at a preset interval; S20A. The stator body (10) is formed by using a first forming device to form the insulating magnetic powder and closely disposed with the plurality of coil windings (20) to form the stator (1).

7. The one-time molding process according to claim 6, characterized in that, Specifically, S20A is: The first forming device is a pressing device. The insulating magnetic powder is placed into the first mold, and the pressing device is used to apply a first preset pressure to the first mold and maintain it for a first preset time to form the stator (1). Alternatively, the first molding device is a metal powder injection molding device, which injects the insulating magnetic powder into the first mold to form the stator (1).

8. A step-by-step forming process, applicable to the stator (1) according to any one of claims 1-5, characterized in that, The step-by-step forming process includes: S10B. The insulating magnetic powder is placed into the second mold, and the second molding device is used to form the insulating magnetic powder into an intermediate transition body (11). The intermediate transition body (11) includes a plurality of limiting parts, which are used to position the plurality of coil windings (20) one by one. S20B, Place the intermediate transition body (11) into the third mold, and set a number of coil windings (20) and a number of limiting parts in a corresponding manner; S30B, The third forming device is used to form the stator (1) from the intermediate transition body (11) and the plurality of coil windings (20).

9. The step-by-step forming process according to claim 8, characterized in that, The intermediate transition body (11) includes a first intermediate transition body (12) and a plurality of second intermediate transition bodies (13). The first intermediate transition body (12) has a plurality of receiving slots (121), which are used to receive a plurality of coil windings (20) in a one-to-one correspondence. The plurality of second intermediate transition bodies (13) can be placed in the interior of the plurality of coil windings (20) in a one-to-one correspondence. S20B is as follows: the first intermediate transition body (12) is placed into the third mold, and a plurality of coil windings (20) are correspondingly set with a plurality of limiting parts, and a plurality of second intermediate transition bodies (13) are placed inside the plurality of coil windings (20).

10. An electric motor, the electric motor comprising a housing (2), a shaft (3), and a rotor (4), characterized in that, The motor further includes a stator (1) as described in any one of claims 1-6, the stator (1) being installed inside the housing (2), the rotating shaft (3) being rotatably disposed on the housing (2), the rotor (4) being fixedly disposed on the rotating shaft (3), and the stator (1) and the rotor (4) being spaced apart.

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