Stator assembly, motor and household appliance

Abstract

The utility model discloses a stator assembly, a motor and a household electrical appliance, and relates to the technical field of motors, and the stator assembly comprises a stator core, a plurality of insulation frames and insulation sheets. The sinking grooves are formed in the two ends of the stator core along the axis respectively, part of structures, located at the two ends of the stator core, of the insulating frames are installed in the sinking grooves, the two ends of the insulating sheets are connected to the two insulating frames respectively, and the insulating sheets are arranged around the inner sides of the winding grooves. The insulation frame does not occupy the area of the winding groove, the thickness of the insulation sheet is smaller than that of the insulation frame, the area of the winding groove is maximized while electrical insulation is guaranteed, and therefore maximization of motor power is achieved under the condition that the outer contour size of the stator assembly is not changed. And the insulation sheets are connected with the insulation frame to ensure the creepage distance, and meanwhile, the span of the winding in the axial direction is reduced, and the copper consumption of the winding is reduced, so that the copper consumption and the manufacturing cost are reduced, and high energy efficiency and low cost of the motor are realized.

Description

Technical Field

[0001] The utility model relates to the technical field of motors, and in particular to a stator assembly, a motor and a household appliance. Background Art

[0002] With the development of the home appliance industry, motors have also been asked to have high power, small size, high energy efficiency and low cost. However, there is a conflict between the high power and small size of motors, and the high energy efficiency of motors also conflicts with low cost. In the related art, after the insulating frame is installed on the two axial ends of the stator core, the insulating frame will occupy the area of ​​the winding slot. In order to meet the energy efficiency requirements, the amount of windings increases, which increases the manufacturing cost and the copper loss. Moreover, since the area of ​​the winding slot is limited, if the power needs to be increased, the area of ​​the winding slot needs to be increased, so the size of the stator core can only be increased. Utility Model Content

[0003] The utility model aims to solve at least one of the technical problems existing in the prior art. To this end, the utility model provides a stator assembly, which can improve the performance of the motor without changing the outer contour size.

[0004] The utility model also provides a motor with the stator assembly.

[0005] According to the stator assembly of the embodiment of the first aspect of the utility model, applied to a motor, it includes: a stator core, arranged around the rotation axis of the motor, the stator core is provided with a plurality of winding slots arranged at intervals along the circumference of the rotation axis, and the two ends of the stator core are respectively provided with sinks along the direction of the rotation axis, wherein two of the sinks are located at the two ends of one of the winding slots and are arranged around the inner side of the winding slot; a plurality of insulating frames, two of which are respectively connected to the two ends of the stator core along the rotation axis, and partial structures of the two insulating frames are installed in the sinks; an insulating sheet, respectively connected to the two insulating frames at the two ends along the rotation axis, and the insulating sheet is arranged around the inner side of the winding slot.

[0006] The stator assembly according to the embodiment of the utility model has at least the following beneficial effects:

[0007] By setting a sink groove at both ends of the stator core along the axis, the partial structure of the insulation frame at both ends of the stator core is installed in the sink groove, and the two ends of the insulation sheet are respectively connected to the two insulation frames, and the insulation sheet is arranged around the inner side of the winding groove. Therefore, the insulation frame does not occupy the area of ​​the winding groove, and the thickness of the insulation sheet is less than the thickness of the insulation frame, which ensures electrical insulation while maximizing the area of ​​the winding groove, so that the winding groove can accommodate windings with more turns, thereby maximizing the power of the motor under the condition that the outer contour size of the stator assembly remains unchanged; and the insulation sheet is connected to the insulation frame to ensure the creepage distance, while reducing the span of the winding in the axial direction, reducing the copper consumption of the winding under the same number of turns, thereby reducing copper loss and manufacturing cost, and achieving high energy efficiency and low cost of the motor.

[0008] According to some embodiments of the utility model, the insulating frame includes a base and wall portions connected to two opposite edges of the base, the base is connected to the end of the stator core, the two wall portions are respectively located in two adjacent grooves, and the insulating sheet is fixedly connected to the wall portions.

[0009] According to some embodiments of the utility model, the side walls of two adjacent sinks are respectively provided with at least one latch hole, and the opposite sides of the two wall portions are respectively provided with at least one buckle, and the buckle is buckled with the latch hole.

[0010] According to some embodiments of the utility model, the stator core includes a yoke and a plurality of stator teeth, the yoke is arranged around the rotation axis, the plurality of stator teeth are arranged around the inner side of the yoke and spaced apart along the circumferential direction, the stator teeth include a tooth portion and a tooth top, one end of the tooth portion is connected to the yoke, and the other end is connected to the tooth top, the tooth top includes two tooth shoes, and the two tooth shoes protrude to both sides of the tooth portion along the circumferential direction respectively; the sink groove includes a first section located at the yoke, a second section located at the tooth portion, and a third section located at the tooth shoe; the wall portion includes a first wall abutting against the first section, a second wall abutting against the second section, and a third wall abutting against the third section; the second sections of two adjacent sink grooves are respectively provided with the clamping holes, and the opposite sides of the two second walls are respectively provided with the buckles.

[0011] According to some embodiments of the present invention, a portion of the structure of the second wall is a thinned structure, and the buckle is connected to the thinned structure.

[0012] According to some embodiments of the utility model, at least two spaced-apart locking holes are provided in the sink along the circumferential direction, and the wall portion located on the side of the base facing the sink is provided with buckles corresponding to the locking holes.

[0013] According to some embodiments of the present invention, along the circumferential direction, the maximum thickness of the wall portion is less than or equal to the minimum width of the sink.

[0014] According to some embodiments of the present invention, along the direction of the rotation axis, the overlapping height between the insulating sheet and each of the insulating frames is greater than or equal to 2.5 mm.

[0015] According to some embodiments of the present invention, the insulating frame includes at least one first boss, and the first boss is used to limit at least one end of the insulating sheet along the rotation axis.

[0016] According to some embodiments of the utility model, the insulating frame includes at least one second boss, and along the direction of the rotation axis, a limiting groove is provided on one side of the second boss facing the other insulating frame, and the insulating sheet is connected to the limiting groove.

[0017] According to some embodiments of the present invention, along the direction of the rotation axis, the notch of the limiting groove gradually increases in a direction away from the base.

[0018] According to some embodiments of the utility model, the stator core includes a yoke and a plurality of stator teeth, the yoke is arranged around the rotation axis, the stator teeth include a tooth portion and a tooth top, one end of the tooth portion is connected to the yoke, and the other end is connected to the tooth top; the insulating frame includes at least one first boss, and the first boss is used to limit at least one end of the insulating sheet along the rotation axis; along the direction around the winding slot, the first boss is arranged at one end of the insulating frame close to the tooth top, and the second boss is arranged at one end of the insulating frame away from the tooth top.

[0019] The motor according to the second embodiment of the utility model includes the stator assembly described in the above embodiment.

[0020] The motor according to the embodiment of the utility model has at least the following beneficial effects:

[0021] The stator assembly of the first aspect embodiment is adopted, and the stator assembly is provided with a sink groove at both ends of the stator core along the axis, and the partial structure of the insulating frame at both ends of the stator core is installed in the sink groove, and the two ends of the insulating sheet are respectively connected to the two insulating frames, and the insulating sheet is arranged around the inner side of the winding groove. Therefore, the insulating frame does not occupy the area of ​​the winding groove, and the thickness of the insulating sheet is less than the thickness of the insulating frame, which ensures electrical insulation while maximizing the area of ​​the winding groove, so that the winding groove can accommodate windings with more turns, thereby maximizing the power of the motor under the condition that the outer contour size of the stator assembly remains unchanged; and the insulating sheet is connected to the insulating frame to ensure the creepage distance, while reducing the span of the winding in the axial direction, reducing the copper consumption of the winding under the same number of turns, thereby reducing copper loss and manufacturing cost, and achieving high energy efficiency and low cost of the motor.

[0022] The household appliance according to the embodiment of the third aspect of the utility model comprises the motor described in the above embodiment.

[0023] Additional aspects and advantages of the present invention will be given in part in the following description, and in part will become apparent from the following description, or will be learned through the practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The present invention is further described below with reference to the accompanying drawings and embodiments, wherein:

[0025] Figure 1 This is a schematic diagram of the structure of a motor according to an embodiment of the utility model, which includes a stator core, a rotor core and a permanent magnet;

[0026] Figure 2 This is a schematic structural diagram of a stator assembly of an embodiment of the utility model, wherein the winding is not shown;

[0027] Figure 3 for Figure 2 An exploded view of the stator assembly is shown;

[0028] Figure 4 It is a partial enlarged view of a stator core of an embodiment of the utility model, wherein two stator teeth are shown;

[0029] Figure 5 This is a structural schematic diagram of a stator core in an initial state according to an embodiment of the utility model;

[0030] Figure 6 It is a partial enlarged view of a stator core of an embodiment of the utility model, wherein a stator tooth is shown;

[0031] Figure 7 This is a cross-sectional view of a stator assembly of an embodiment of the utility model, which shows Figure 6The stator teeth shown and the insulating frame matched therewith;

[0032] Figure 8 A partial enlarged view of a stator core of another embodiment of the utility model, wherein a stator tooth is shown;

[0033] Fig. 9 This is a cross-sectional view of a stator assembly of another embodiment of the utility model, which shows Figure 8 The stator teeth shown and the insulating frame matched therewith;

[0034] Fig.10 A cross-sectional view of a stator assembly according to another embodiment of the present utility model;

[0035] Fig.11 An insulating frame of an embodiment of the utility model;

[0036] Fig.12 The insulating frame of another embodiment of the utility model is Fig.11 The insulating frames shown are mounted on Figure 8 The two ends of the stator core are shown;

[0037] Fig.13 An insulating frame of another embodiment of the utility model;

[0038] Fig.14 The insulating frame of another embodiment of the utility model is Fig.13 The insulating frames shown are mounted on Figure 6 The two ends of the stator core are shown.

[0039] Figure Number:

[0040] stator assembly 100; stator core 110; yoke 111; first yoke 1111; second yoke 1112; stator tooth 112; tooth 113; tooth top 114; tooth shoe 1141; first tooth shoe 1142; second tooth shoe 1143; protrusion 115; groove 116; welding feature 117; clamping hole 118; insulation frame 120; base 121; wall 122; first wall 1221; Second wall 1222; third wall 1223; first chamfer 1224; thinning structure 1225; buckle 123; first boss 124; second boss 125; limiting groove 126; second notch 1261; second chamfer 1262; winding groove 130; first notch 131; sink 140; first sink 141; second sink 142; first section 143; second section 144; third section 145;

[0041] Rotor assembly 200; rotor core 210; permanent magnet 220;

[0042] Insulation sheet 300;

[0043] Axis of rotation O. DETAILED DESCRIPTION

[0044] The embodiments of the present invention are described in detail below, and examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and cannot be understood as limiting the present invention.

[0045] In the description of the present invention, it should be understood that the descriptions involving orientation, such as the orientation or positional relationship indicated as up, down, etc., are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0046] In the description of the present utility model, "a plurality" means more than two. If there is a description of "first" or "second", it is only for the purpose of distinguishing the technical features, and cannot be understood as indicating or implying the relative importance or implicitly indicating the number of the indicated technical features or implicitly indicating the order of the indicated technical features.

[0047] In the description of the present invention, unless otherwise clearly defined, terms such as setting, installing, connecting, etc. should be understood in a broad sense, and technicians in the relevant technical field can reasonably determine the specific meanings of the above terms in the present invention based on the specific content of the technical solution.

[0048] Motors are important components in household appliances, for example, motors used to drive the fan of air conditioners, motor components inside compressors, motors for washing machines, motors for dishwashers, etc. With the development of the household appliance industry, motors are also required to be high-power, small, energy-efficient and low-cost.

[0049] The motor generally includes a stator assembly and a rotor assembly, wherein the rotor assembly rotates around the rotation axis of the motor, and the stator assembly is arranged around the rotation axis. Under the action of the electromagnetic field, the rotor assembly can rotate relative to the stator assembly, thereby driving the load connected to the output end of the motor to rotate. It can be understood that in one embodiment, the stator assembly is configured to be arranged around the outside of the rotor assembly, that is, an inner rotor motor; in another embodiment, the stator assembly is configured to be arranged around the inside of the rotor assembly, that is, an outer rotor motor.

[0050] In order to facilitate understanding of the solutions of the embodiments of the present utility model, the following description is given by taking an inner rotor motor as an example.

[0051] Reference Figure 1As shown, the inner rotor motor includes a stator assembly 100 and a rotor assembly 200. The rotor assembly 200 includes a rotating shaft, the central axis of the rotating shaft coincides with the rotation axis O of the motor, and the stator assembly 100 is arranged around the outer side of the rotor assembly 200. In order to improve the stability and reliability of the motor, the rotor assembly 200 and the stator assembly 100 are generally respectively subjected to plastic overmolding treatment before being assembled. The rotor assembly 200 includes a rotor core 210, a plurality of permanent magnets 220 and a rotating shaft. The rotor core 210 is provided with a plurality of mounting grooves, and the plurality of permanent magnets 220 are mounted one by one in the corresponding mounting grooves. The rotating shaft is mounted inside the rotor core 210. The assembled rotor core 210, the plurality of permanent magnets 220 and the rotating shaft are connected by an integrated injection molding process, which is the plastic overmolding treatment of the rotor assembly 200. Refer to Figure 2 As shown, the stator assembly 100 includes a stator core 110, an insulating frame 120 and a winding. The assembled stator core 110, the insulating frame 120 and the winding are connected by an integrated injection molding process, which is the overmolding treatment of the stator assembly 100. It should be noted that the overmolding treatment of the stator assembly 100 generally forms a part of the motor housing at the same time, so as to facilitate the installation of the rotor assembly 200. After the overmolding treatment, the rotor assembly 200 and the stator assembly 100 can both obtain a more stable structure, so that the internal components are not easily separated, and the connection stability between the components is improved.

[0052] Reference Figure 3 and Figure 4 As shown, a stator assembly 100 according to an embodiment of the utility model, the stator core 110 is arranged along the circumferential direction of the rotation axis O. The stator core 110 includes a yoke 111 and a plurality of stator teeth 112, the yoke 111 is arranged around the outer side of the rotor assembly 200, and the plurality of stator teeth 112 are arranged around the inner side of the yoke 111, and the plurality of stator teeth 112 are spaced apart along the circumferential direction, and along the radial direction of the stator core 110, the plurality of stator teeth 112 are spaced apart from the rotor assembly 200 on one side away from the yoke 111. Each stator tooth 112 includes a tooth portion 113 and a tooth top 114, one end of each tooth portion 113 is connected to the yoke 111, and the other end of each tooth portion 113 is connected to the tooth top 114, and the tooth top 114 is spaced apart from the rotor assembly 200. Refer to Figure 1As shown, an air gap is formed between the tooth top 114 and the rotor assembly 200, and the air gap is a non-uniform air gap along the circumferential direction, thereby improving the performance of the motor. In order to achieve a non-uniform air gap, a motor of an embodiment of the utility model sets the outer contour of the rotor core 210 to a multi-segment line; or sets the outer contour of the rotor core 210 to an arc that is not coaxial with the rotation axis O. As an alternative embodiment, the motor can also set the gap between each tooth top 114 and the rotor assembly 200 to be different; or set the inner contour of at least one tooth top 114 facing the side of the rotor assembly 200 to a multi-segment line or an arc that is not coaxial with the rotation axis O, so that the gap between the tooth top 114 and the rotor assembly 200 is different along the circumferential direction.

[0053] Reference Figure 1 and Figure 4 As shown, the stator core 110 is provided with a plurality of winding slots 130, and the plurality of winding slots 130 are arranged at intervals along the circumferential direction of the rotation axis O. Each winding slot 130 is formed by enclosing two adjacent stator teeth 112 and a yoke 111 connected between the two stator teeth 112. Two circumferentially adjacent stator teeth 112 are provided with a gap on a side close to the rotor assembly 200, and the gap is formed as a first notch 131 of the winding slot 130. The design of the first notch 131 facilitates the winding to be wound around the stator teeth 112. The stator core 110 of the embodiment of the utility model adopts a linearly arranged structure (such as Figure 5 The stator core 110 is in a strip-shaped state as shown in the figure, so that the winding slot 130 between the two stator teeth 112 can be opened in the initial state, that is, the first notch 131 of the winding slot 130 is opened, which facilitates the enameled wire to enter the winding slot 130 during winding, which is beneficial to improve the winding efficiency. After the winding is completed, the stator core 110 is re-formed into a full circle (that is, the annular stator core 110, as shown in the figure). Figure 2 As shown), and the installation method of this embodiment does not require the reserved width of the winding needle, and can maximize the use of limited space to wind more enameled wires, improve the slot fill rate, and thus achieve the goal of high-power miniaturization of the motor.

[0054] Reference Figure 5 As shown, the stator assembly 100 of the embodiment of the utility model adopts a linear arrangement and then rounded assembly method. The stator core 110 has a bending portion or a chain-type matching portion in the middle position of the two stator teeth 112. The bending portion or the chain-type matching portion can be arranged on the yoke 111 between the two stator teeth 112. During assembly, the stator core 110 in a bar state can be bent into a stator core 110 in a full circle state by bending the bending portion or the chain-type matching portion. Therefore, the bending portion or the chain-type matching portion can ensure the accuracy of the relative position of the two stator teeth 112 after rotation and the integrity of the connection.

[0055] Reference Figure 5As shown, the stator core 110 in the bar state has a protrusion 115 on one side along the length direction and a groove 116 on the other side. The protrusion 115 and the groove 116 can fit tightly after being rounded. The cooperation between the protrusion 115 and the groove 116 enables the stator core 110 to achieve the rounded position positioning, ensuring the accuracy of the relative position of the first and last two stator teeth 112 along the length direction of the stator core 110. In this embodiment, the outer contour of the protrusion 115 is a cylindrical surface, and the inner contour of the groove 116 is a cylindrical surface that matches the protrusion 115.

[0056] Reference Figure 5 As shown, in order to ensure the overall stability of the stator core 110 after being rounded, the stator core 110 in a bar state has welding features 117 on both sides along the length direction.

[0057] Reference Figure 6 and Figure 8 As shown, along the direction of the rotation axis O, the two ends of the stator core 110 are respectively provided with a sink groove 140. In the embodiment of the utility model, both ends of all the winding slots 130 of the stator core 110 are respectively provided with a sink groove 140, and the sink groove 140 is arranged around the inner side of the winding slot 130. It can be understood that the sink groove 140 is configured to be arranged around the inner contour of the entire winding slot 130; as an alternative embodiment, the sink groove 140 can also be configured to be arranged around a part of the inner contour of the winding slot 130; for example, the sink groove 140 is only provided on the tooth portion 113 and the part of the yoke portion 111 close to the tooth portion 113. In this embodiment, it is sufficient as long as the sink groove 140 can be arranged at all the winding positions.

[0058] In another embodiment of the utility model, both ends of some winding slots 130 of the stator core 110 are provided with recessed grooves 140, and both ends of the other winding slots 130 are not provided with recessed grooves 140; for example, along the circumferential direction, the winding slots 130 provided with recessed grooves 140 and the winding slots 130 without recessed grooves 140 are arranged alternately. Alternatively, the recessed grooves 140 are provided on the part of the inner contour close to one of the two tooth portions 113, and the recessed grooves 140 are not provided on the part of the inner contour close to the other tooth portion 113. When the performance requirements of the motor do not require the use of all the winding slot 130 space, the design of the recessed grooves 140 can be eliminated in some winding slots 130; in addition, from the perspective of cost saving, a design in which some stator teeth 112 are not wound can also be adopted.

[0059] In order to ensure the electrical insulation requirements between the winding and the stator core 110, the stator core 110 is installed with an insulating frame 120 at both ends along the rotation axis O, and the winding is wound on the insulating frame 120, so the number of insulating frames 120 is related to the number of winding slots 130 (or stator teeth 112) of the stator core 110. Since the insulating frame 120 of the traditional motor is designed to be inserted at both ends along the rotation axis O, the thickness of the insulating frame 120 is relatively large, which will occupy more area of ​​the winding slot 130. Therefore, the sinking groove 140 of the embodiment of the utility model is used to accommodate part of the structure of the insulating frame 120, so that when the insulating frame 120 is installed at the end of the stator core 110, the part of the structure extending to the winding slot 130 can be accommodated in the sinking groove 140, so that the insulating frame 120 will not protrude from the winding slot 130 and will not occupy the original design space of the winding slot 130. In addition, the depth of the groove 140 along the direction of the rotation axis O cannot be too large, otherwise the overall width of the tooth portion 113 is reduced, resulting in a narrower magnetic circuit, too high magnetic density, increased magnetic saturation, and reduced performance of the motor.

[0060] Reference Figure 7 and Fig. 9 As shown, in order to solve the above problems, the stator assembly 100 of the embodiment of the utility model is additionally provided with an insulating sheet 300, and the thickness of the insulating sheet 300 is significantly less than the thickness of the plug-in wall of the insulating frame 120 of the traditional motor. The insulating sheet 300 can be made of insulating paper with a smaller thickness, or other thin sheet materials with insulating properties. Along the two ends of the rotation axis O, the insulating sheet 300 is respectively connected to the two insulating frames 120, and the insulating sheet 300 can be connected to the insulating frame 120 by bonding, clamping, screw connection, etc. The insulating sheet 300 is arranged around the inner side of the winding groove 130, and each winding groove 130 is respectively provided with an insulating sheet 300, and the insulating sheet 300 is fitted with the inner wall of the winding groove 130, so that when the enameled wire is wound on the insulating frame 120, the insulating sheet 300 plays a role of electrical insulation between the winding and the stator core 110.

[0061] As an alternative embodiment, the entire stator assembly 100 is provided with one insulating sheet 300 and is configured to be continuously arranged in a plurality of winding slots 130. Of course, the stator assembly 100 may also be provided with multiple insulating sheets 300, each insulating sheet 300 being configured to be continuously arranged in at least two winding slots 130.

[0062] The insulating frame 120 of the embodiment of the utility model does not occupy the area of ​​the winding slot 130, and uses a thinner insulating sheet 300 to achieve insulation between the enameled wire and the stator core 110, ensuring electrical insulation while maximizing the area of ​​the winding slot 130, so that the winding slot 130 can accommodate windings with more turns. Due to the increase in the area of ​​the winding slot 130, the number of turns that can be wound in the first layer close to the tooth portion 113 increases, and the number of turns that can be wound in each subsequent layer also increases accordingly; when the same number of turns is wound, the length of the copper wire required in this embodiment is shorter, reducing the copper consumption of the winding, thereby reducing copper loss and manufacturing costs. When the outer contour size of the stator assembly 100 remains unchanged, the power of the motor is increased by increasing the number of turns of the winding. In addition, the insulating sheet 300 ensures the creepage distance by being connected to the insulating frame 120. Compared with the conventional motor in which the insulating frame 120 is directly installed on the stator core 110 without providing the recessed groove 140, the axial span of the winding can be reduced. With the same number of turns, the length of the copper wire required in this embodiment is shorter, which reduces the copper consumption of the winding, thereby reducing copper loss and manufacturing cost, and achieving high energy efficiency and low cost of the motor.

[0063] Moreover, the stator assembly 100 of this embodiment can maximize the area of ​​the winding slot 130, maximize the slot fill rate, and minimize the amount of copper used, thereby improving the performance of the motor; the motor equipped with the stator of the above embodiment can achieve high power, miniaturization, high efficiency, and low cost, and has good manufacturability and product reliability.

[0064] Reference Figure 7 , Fig.11 and Fig.12 As shown, it can be understood that the insulating frame 120 includes a base 121 and a wall 122. The base 121 is connected to the end of the stator core 110, and the wall 122 is connected to the two opposite edges of the base 121. The two wall portions 122 are respectively located in two adjacent sinking grooves 140. In two circumferentially adjacent winding grooves 130, the base 121 is connected to the stator teeth 112 between the two winding grooves 130 and the part of the yoke 111 connected to both sides of the stator teeth 112, the wall portion 122 on one side of the base 121 is built into the sinking groove 140 of one winding groove 130, and the wall portion 122 on the other side of the base 121 is built into the sinking groove 140 of the other winding groove 130. The insulating frame 120 can be connected to the tooth portion 113 through the slots formed by the wall portions 122 on both sides.

[0065] The insulating sheet 300 is fixedly connected to the wall portion 122, and the insulating sheet 300 and the wall portion 122 are fixed by bonding, clamping, screw connection, etc. In order to meet the requirements of the creepage distance, the wall portion 122 and the insulating sheet 300 of each insulating frame 120 need to meet a certain overlap distance, so the axial size of the wall portion 122 needs to be designed according to the creepage distance. Fig.10 As shown, along the axial direction, the overlapping height h of the insulating sheet 300 and the corresponding two insulating frames 120 is greater than or equal to 2.5 mm. The insulating sheet 300 and the two insulating frames 120 referred to here correspond to the insulating sheet 300 and the insulating frame 120 with windings wound thereon. Therefore, setting the overlapping height of the wall portion 122 of the insulating frame 120 for winding the windings and the insulating sheet 300 to be greater than or equal to 2.5 mm can meet the design requirements of the motor for the creepage distance and ensure the safety of the motor. It is understandable that the length of the wall portion 122 along the axial direction can also be set to be greater than or equal to 2.5 mm, so as to ensure the creepage distance.

[0066] Reference Figure 6 and Figure 7 As shown, in order to improve the connection reliability between the insulating frame 120 and the stator core 110, the stator core 110 of the embodiment of the utility model is provided with a clamping hole 118, and the clamping hole 118 is located on the side wall of the sink 140, and the side wall is the side wall of the sink 140 surrounding the winding groove 130 and facing the center of the winding groove 130. The buckle 123 matched with the clamping hole 118 is arranged on the wall portion 122, and the wall portion 122 realizes the stable connection between the insulating frame 120 and the stator core 110 through the cooperation of the buckle 123 and the clamping hole 118, thereby improving the manufacturability. In this embodiment, the side walls of two adjacent sinks 140 are respectively provided with at least one clamping hole 118, and the opposite sides of the two wall portions 122 are respectively provided with at least one clamping hole 118.

[0067] It is understandable that the insulating frame 120 is generally a plastic part, and the buckle 123 can be integrally injection molded with the insulating frame 120. In this embodiment, the stator core 110 includes a plurality of stator punchings stacked along the direction of the rotation axis O, and the plurality of stator punchings are connected by rivet holes to form a stator core 110 with a certain thickness. The stator punchings can be made of ultra-thin silicon steel plates to minimize iron loss and achieve the ultra-high efficiency goal of the motor.

[0068] In some embodiments, the stator core 110 can be punched out into stator punching sheets with different structures through a stamping process, and some stator punching sheets have notch structures with different structural sizes at the positions where the clamping holes 118 are formed, so that different stator punching sheets are stacked to form the clamping holes 118. In another embodiment, the stator core 110 is an integral structure rather than being stacked by stator punching sheets, and in this case, the clamping holes 118 can be directly processed on the surface of the stator core 110.

[0069] Reference Figure 4As shown, in the stator assembly 100 of the embodiment of the utility model, the tooth top 114 includes two tooth shoes 1141, and the two tooth shoes 1141 are respectively a first tooth shoe 1142 and a second tooth shoe 1143. In the circumferential direction, the first tooth shoe 1142 is formed by the tooth top 114 protruding to the winding groove 130 on one side of the tooth portion 113, and the second tooth shoe 1143 is formed by the tooth top 114 protruding to the winding groove 130 on the other side of the tooth portion 113. The yokes 111 on both sides of the tooth portion 113 in the circumferential direction are respectively a first yoke 1111 and a second yoke 1112. During the winding process, the positions where the enameled wire contacts the insulating frame 120 are mainly corresponding to the positions of the tooth portion 113, the positions corresponding to the first tooth shoe 1142 and the second tooth shoe 1143, and the positions corresponding to the first yoke 1111 and the second yoke 1112 close to the tooth portion 113.

[0070] The following description is made by taking the insulating frame 120 at one end along the direction of the rotation axis O as an example and installing it in the sink 140 at the corresponding position. It can be understood that along the direction of the rotation axis O, the two insulating frames 120 at both ends of the stator tooth 112 are generally configured as the same structure, but different embodiments of the present invention can also be used according to actual assembly.

[0071] Along the circumferential direction, the sunken grooves 140 located on both sides of the tooth portion 113 are respectively the first sunken groove 141 and the second sunken groove 142. The partial groove section of the first sunken groove 141 close to the tooth portion 113 and the partial groove section of the second sunken groove 142 close to the tooth portion 113 both include a first section 143, a second section 144 and a third section 145 connected in sequence. The first section 143 of the first sunken groove 141 is located at the end of the first yoke 1111, the second section 144 is located at one side of the end of the tooth portion 113, and the third section 145 is located at the end of the first tooth shoe 1142. The first section 143 of the second sunken groove 142 is located at the end of the second yoke 1112, the second section 144 is located at the other side of the end of the tooth portion 113, and the third section 145 is located at the end of the second tooth shoe 1143.

[0072] Along the circumferential direction, the two wall portions 122 of the insulating frame 120 are respectively installed in the first sinking groove 141 and the second sinking groove 142. Fig.11 As shown, both wall portions 122 include a first wall 1221, a second wall 1222 and a third wall 1223. The first wall 1221 abuts against and is located in the first section 143, the second wall 1222 abuts against and is located in the second section 144, and the third wall 1223 abuts against and is located in the third section 145.

[0073] Reference Figure 6 , Figure 7 and Fig.11As shown, in some embodiments, the second section 144 of the first sink 141 and the second section 144 of the second sink 142 are respectively provided with a clamping hole 118, and the opposite sides of the two second walls 1222 are respectively provided with a clamping buckle 123. The clamping buckle 123 is buckled with the corresponding clamping hole 118, and the number of the clamping buckles 123 is the same as the number of the clamping holes 118, so that the insulation frame 120 is stably connected to the end of the stator core 110. The clamping hole 118 is arranged in the second section 144, which can conveniently provide space for the connection of the clamping buckle 123 of the insulation frame 120, and the clamping buckles 123 distributed on both sides of the tooth portion 113 can be used with a smaller number of buckles 123 to achieve a stable connection between the insulation frame 120 and the stator core 110.

[0074] Reference Figure 8 , Fig. 9 and Fig.13 As shown, in other embodiments, the first section 143 and the third section 145 of the first sink 141 or the second sink 142 are respectively provided with a clamping hole 118, and along the circumferential direction, the first wall 1221 and the third wall 1223 located on the same side of the base 121 are respectively provided with a buckle 123. The buckle 123 is buckled with the corresponding buckle 118, and the number of the buckle 123 is the same as the number of the buckle 118, so that the insulation frame 120 is stably connected to the end of the stator core 110.

[0075] Reference Figure 8 , Fig. 9 , Fig.13 and Fig.14 As shown, in other embodiments, the first sink 141 without the second section 144 and the second sink 142 without the second section 144 are respectively provided with at least one clamping hole 118, and along the circumferential direction, the base 121 is respectively provided with a clamp 123 that is buckled with the clamping hole 118 on one side close to the first sink 141 and on one side close to the second sink 142, so that the insulating frame 120 is stably connected to the end of the stator core 110. For example, this embodiment includes one of the following four situations:

[0076] The first type: the first section 143 of the first groove 141 and the third section 145 of the second groove 142 are respectively provided with a clamping hole 118, and along the circumferential direction, the first wall 1221 of the base 121 close to the first groove 141 and the third wall 1223 close to the second groove 142 are respectively provided with a buckle 123 that cooperates with the clamping hole 118 at the corresponding position.

[0077] The second type: the first section 143 of the first groove 141 and the first section 143 of the second groove 142 are respectively provided with a clamping hole 118, and along the circumferential direction, the first wall 1221 of the base 121 close to the first groove 141 and the first wall 1221 close to the second groove 142 are respectively provided with a buckle 123 that cooperates with the clamping hole 118 on the first section 143.

[0078] The third type: the third section 145 of the first groove 141 and the third section 145 of the second groove 142 are respectively provided with a clamping hole 118, and along the circumferential direction, the third wall 1223 of the base 121 close to the first groove 141 and the third wall 1223 close to the second groove 142 are respectively provided with a buckle 123 that cooperates with the clamping hole 118 on the third section 145.

[0079] The fourth type: the first section 143 and the third section 145 of the first groove 141, and the first section 143 and the third section 145 of the second groove 142 are respectively provided with a clamping hole 118, and along the circumferential direction, the first wall 1221 and the third wall 1223 of the base 121 close to the first groove 141, and the first wall 1221 and the third wall 1223 close to the second groove 142 are respectively provided with a buckle 123 that cooperates with the clamping hole 118 on the first section 143 and the third section 145.

[0080] It can be understood that, by adopting the above four embodiments, since the buckles 123 provided on the first wall 1221 and the third wall 1223 of the insulation frame 120 are easier to deform, the manufacturability can be improved.

[0081] Reference Fig.11 and Fig.12 As shown, in the insulating frame 120 of the present embodiment, the end of the wall 122 away from the base 121 has a first chamfer 1224, and the first chamfer 1224 is arranged on the side close to the stator core 110, so as to facilitate the introduction of the insulating frame 120 into the stator core 110, thereby making the installation of the insulating frame 120 more convenient and the manufacturability better.

[0082] Reference Fig.11 As shown, in one embodiment of the utility model, the wall portion 122 includes a second wall 1222, and two second walls 1222 arranged opposite to each other are inserted into the end of the tooth portion 113, and the second wall 1222 abuts against the side wall of the sink 140. Part of the structure of the second wall 1222 is a thinning structure 1225, and the buckle 123 is connected to the thinning structure 1225. The wall thickness of the thinning structure 1225 is less than the wall thickness of other positions of the wall portion 122, and the buckle 123 is arranged in the thinning structure 1225, so that the buckle 123 is easy to deform, easier to install, and has better manufacturability.

[0083] Reference Fig.10 As shown, in one embodiment of the present invention, along the circumferential direction, the maximum thickness of the wall portion 122 is less than or equal to the minimum width of the sinking groove 140, that is, the maximum wall thickness of the wall portion 122 is less than or equal to the minimum width of the sinking groove 140. Therefore, after the insulating frame 120 is installed to the stator core 110, the wall portion 122 will not protrude into the winding groove 130, so that the insulating frame 120 does not occupy the area of ​​the winding groove 130, thereby improving the efficiency and manufacturability of the motor.

[0084] Reference Fig.11 and Fig.13 As shown, in one embodiment of the utility model, the insulating frame 120 includes a first boss 124 protruding to the winding groove 130, and the first boss 124 is connected to the base 121 or the wall 122. In order to meet the manufacturability and reliability, the first boss 124 is integrally formed with the base 121 and the wall 122. One or more first bosses 124 are provided. When there are multiple first bosses 124, the multiple first bosses 124 are spaced apart in the direction around the winding groove 130 on the base 121 or the wall 122. The first boss 124 is used to limit one end of the insulating sheet 300 along the direction of the rotation axis O. When the two insulating frames 120 at both ends of the stator core 110 along the direction of the rotation axis O are respectively provided with the first boss 124, the first bosses 124 at both ends jointly position the axial ends of the insulating sheet 300, limit the axial movement of the insulating sheet 300, ensure the installation reliability of the insulating sheet 300, thereby facilitating the winding operation of the winding and ensuring the reliability of the electrical insulation of the motor.

[0085] Reference Figure 7 , Fig.12 and Fig.14 As shown, in another embodiment of the utility model, the insulating frame 120 includes a second boss 125 protruding to the winding groove 130, and the second boss 125 is connected to the base 121 or the wall 122. In order to meet the manufacturability and reliability, the second boss 125 is integrally formed with the base 121 and the wall 122. There is one or more second bosses 125, and when there are multiple second bosses 125, the multiple second bosses 125 are spaced apart and arranged on the base 121 or the wall 122 along the direction around the winding groove 130.

[0086] Along the direction of the rotation axis O, a limiting groove 126 is provided on one side of the second boss 125 facing the other insulating frame 120, that is, the second notch 1261 of the limiting groove 126 faces the insulating sheet 300, and one end of the insulating sheet 300 along the direction of the rotation axis O is connected to the limiting groove 126. It can be understood that the limiting groove 126 can be formed inside the second boss 125, or at the connection between the second boss 125 and the wall portion 122, which is not specifically limited here. When the two insulating frames 120 at both ends of the stator core 110 along the direction of the rotation axis O are respectively provided with the second boss 125, the limiting grooves 126 of the second boss 125 at both ends jointly position the axial ends of the insulating sheet 300, limit the axial movement of the insulating sheet 300, ensure the installation reliability of the insulating sheet 300, thereby facilitating the winding operation of the winding and ensuring the reliability of the electrical insulation of the motor.

[0087] Reference Fig.11 and Fig.12 ,as well as Fig.13 and Fig.14 As shown, the limiting groove 126 penetrates the second boss 125 in the direction around the winding groove 130, so that the two side walls of the limiting groove 126 are parallel to the corresponding partial structure of the wall portion 122. It can be understood that along the direction of the rotation axis O, the second notch 1261 of the limiting groove 126 gradually increases in the direction away from the base 121, so that the side wall of the limiting groove 126 forms a second chamfer 1262 at the position of the second notch 1261. The second chamfer 1262 can be provided on one of the two side walls of the limiting groove 126, or on both side walls at the same time. When one of the side walls of the limiting groove 126 is the outer side wall of the wall portion 122, the second chamfer 1262 can also be provided at one end of the wall portion 122 away from the base 121.

[0088] In order to facilitate the installation of the insulating sheet 300, the insulating frame 120 of the embodiment of the utility model adopts one or more boss structures of the first boss 124 or the second boss 125. Each insulating frame 120 is not limited to using one boss structure. The insulating frames 120 located at both ends of the stator core 110 can respectively adopt different boss structures to achieve stable installation of the insulating sheet 300.

[0089] In the embodiment of the utility model, in order to improve the installation efficiency of the insulating sheet 300, the first insulating frame located at one end of the stator core 110 along the direction of the rotation axis O includes a first boss 124 and a second boss 125. Along the direction around the winding groove 130, the first boss 124 is provided at one end of the first insulating frame close to the tooth top 114, and the second boss 125 is provided at one end of the first insulating frame away from the tooth top 114. Therefore, the insulating sheet 300 can be positioned by the limiting groove 126 at the first notch 131 of the winding groove 130, and the two sides of the first notch 131 of the winding groove 130 are positioned by the limiting groove 126 respectively, so that the entire insulating sheet 300 can be stably connected in the winding groove 130. The second insulating frame located at the other end of the stator core 110 includes two first bosses 124. Along the direction around the winding slot 130, one of the first bosses 124 is arranged at one end of the second insulating frame close to the tooth top 114, and the other first boss 124 is arranged at one end of the second insulating frame away from the tooth top 114.

[0090] As an alternative embodiment, the first insulating frame includes a first boss 124, and the second insulating frame includes a second boss 125. The positions of the first boss 124 and the second boss 125 are staggered or adjacent in the direction around the winding groove 130, which is not specifically limited here. In another embodiment, the first insulating frame and the second insulating frame are both composed of the first boss 124; or both are composed of the second boss 125.

[0091] In this embodiment, the maximum thickness of the stator punching sheet is t, which satisfies: 0.2mm≤t≤0.35mm. Stator punching sheets generally use silicon steel plates as raw materials. The thickness of silicon steel plates is generally uniform, but there are certain errors. When the stator punching sheets are made of only one specification of silicon steel plates, t is based on the maximum thickness of the silicon steel plates of this specification. Of course, the stator assembly 100 can also be made of silicon steel plates of multiple specifications stacked together. In this case, t is based on the maximum thickness of the silicon steel plate with the largest thickness. The maximum thickness of the silicon steel plate can be directly measured by a vernier caliper. It can be understood that the stator assembly 100 uses stator punching sheets with a maximum thickness t in the thickness range of 0.2mm to 0.35mm, which can effectively reduce iron losses and achieve the goal of ultra-high efficiency of the motor under the condition of controllable cost and controllable manufacturing difficulty.

[0092] The motor of an embodiment of the utility model comprises a rotor assembly 200 and the stator assembly 100 of the above embodiment. The rotor assembly 200 comprises a rotating shaft and a permanent magnet 220. When the winding of the stator assembly 100 is energized, a magnetic field is generated in the stator assembly 100. The magnetic field interacts with the magnetic field of the permanent magnet 220 to generate a torque, thereby driving the rotor to rotate, and then driving the rotating shaft to rotate, so that the motor starts to run. The motor of the embodiment of the utility model adopts the stator assembly 100 of the embodiment of the first aspect. The stator assembly 100 is provided with a sinking groove 140 at both ends of the stator core 110 along the axis, and the partial structure of the insulating frame 120 at both ends of the stator core 110 is installed in the sinking groove 140, and the two ends of the insulating sheet 300 are respectively connected to the two insulating frames 120, and the insulating sheet 300 is arranged around the inner side of the winding groove 130. Therefore, the insulating frame 120 will not occupy the area of ​​the winding groove 130, and the thickness of the insulating sheet 300 is smaller than the thickness of the insulating frame 120, thereby ensuring electrical insulation while maximizing the area of ​​the winding groove 130, so that the winding groove 130 can accommodate windings with more turns, thereby maximizing the motor power while keeping the outer contour dimensions of the stator assembly 100 unchanged; and the insulating sheet 300 is connected to the insulating frame 120 to ensure the creepage distance while reducing the axial span of the winding and the copper usage of the winding with the same number of turns, thereby reducing copper loss and manufacturing costs, and achieving high energy efficiency and low cost of the motor.

[0093] Since the motor of the utility model embodiment adopts all the technical solutions of the stator assembly of the above embodiment, it has at least all the beneficial effects brought by the technical solutions of the above embodiment, which will not be repeated here.

[0094] A household appliance of an embodiment of the utility model comprises the motor of the above embodiment. Since the household appliance of the utility model adopts all the technical solutions of the motor of the above embodiment, it has at least all the beneficial effects brought by the technical solutions of the above embodiment, which will not be described in detail here.

[0095] The embodiments of the present invention are described in detail above in conjunction with the accompanying drawings, but the present invention is not limited to the above embodiments, and various changes can be made within the knowledge scope of ordinary technicians in the relevant technical field without departing from the purpose of the present invention.

Claims

1. A stator assembly, applied to a motor, characterized in that: include: A stator core is arranged around the rotation axis of the motor, and along the circumference of the rotation axis, the stator core is provided with a plurality of winding slots arranged at intervals, and along the direction of the rotation axis, two ends of the stator core are respectively provided with sunken slots, wherein two sunken slots are located at the two ends of one of the winding slots and are arranged around the inner side of the winding slot; A plurality of insulating frames, two of which are respectively connected to the two ends of the stator core along the rotation axis, and parts of the structures of the two insulating frames are installed in the sink; An insulating sheet is respectively connected to the two insulating frames along two ends of the rotating axis, and the insulating sheet is arranged around the inner side of the winding groove.

2. The stator assembly according to claim 1, characterized in that: The insulating frame includes a base and walls connected to two opposite edges of the base, the base is connected to the end of the stator core, the two walls are respectively located in two adjacent sinks, and the insulating sheet is fixedly connected to the wall.

3. The stator assembly according to claim 2, characterized in that: The side walls of two adjacent sinks are respectively provided with at least one clamping hole, and the opposite sides of the two wall portions are respectively provided with at least one clamping buckle, and the clamping buckle is buckled with the clamping hole.

4. The stator assembly according to claim 3, characterized in that: The stator core comprises a yoke and a plurality of stator teeth, wherein the yoke is arranged around the rotation axis, the plurality of stator teeth are arranged around the inner side of the yoke and are arranged at intervals along the circumferential direction, the stator teeth comprise a tooth portion and a tooth top, one end of the tooth portion is connected to the yoke, and the other end is connected to the tooth top, the tooth top comprises two tooth shoes, and the two tooth shoes protrude to both sides of the tooth portion along the circumferential direction respectively; The sink includes a first section located at the yoke, a second section located at the tooth portion, and a third section located at the tooth shoe; The wall portion includes a first wall abutting against the first section, a second wall abutting against the second section, and a third wall abutting against the third section; The second sections of two adjacent sinks are respectively provided with the clamping holes, and the opposite sides of two second walls are respectively provided with the clamping buckles.

5. The stator assembly according to claim 4, characterized in that: A portion of the second wall is a thinned structure, and the buckle is connected to the thinned structure.

6. The stator assembly according to claim 2, characterized in that: Along the circumferential direction, at least two intervally arranged locking holes are provided in the sink, and the wall portion located on the side of the base facing the sink is provided with buckles corresponding to the locking holes.

7. The stator assembly according to claim 2, characterized in that: Along the circumferential direction, the maximum thickness of the wall portion is less than or equal to the minimum width of the sink.

8. The stator assembly according to claim 1 or 7, characterized in that: Along the direction of the rotation axis, the overlapping height between the insulating sheet and each of the insulating frames is greater than or equal to 2.5 mm.

9. The stator assembly according to claim 2, characterized in that: The insulating frame includes at least one first boss, and the first boss is used to limit at least one end of the insulating sheet along the rotation axis.

10. The stator assembly according to claim 2, characterized in that: The insulating frame comprises at least one second boss, and along the direction of the rotation axis, a limiting groove is provided on one side of the second boss facing the other insulating frame, and the insulating sheet is connected in the limiting groove.

11. The stator assembly according to claim 10, characterized in that: Along the direction of the rotation axis, the notch of the limiting groove gradually increases in a direction away from the base.

12. The stator assembly according to claim 10 or 11, characterized in that: The stator core comprises a yoke and a plurality of stator teeth, wherein the yoke is arranged around the rotation axis, and the stator teeth comprise a tooth portion and a tooth top, wherein one end of the tooth portion is connected to the yoke, and the other end is connected to the tooth top; The insulating frame includes at least one first boss, which is used to limit at least one end of the insulating sheet along the rotation axis; along the direction around the winding groove, the first boss is arranged at one end of the insulating frame close to the tooth top, and the second boss is arranged at one end of the insulating frame away from the tooth top.

13. The motor is characterized by: A stator assembly comprising any one of claims 1 to 12.

14. A household appliance, characterized in that: Including the motor as claimed in claim 13.

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