Segmented stator core

Abstract

The utility model provides a segmented stator core, a coil is wound around the segmented stator core, the segmented stator core comprises a first core part comprising a first core, the first core comprises a first groove, and the first groove is a hole for the coil to insert; a second core member including a second slot, the second slot being a hole into which the coil is inserted, and the second core member including a 2-1 core and a 2-2 core disposed on both sides of the first core member; and a third core member including a third slot, the third slot being a hole into which the coil is inserted, and the third core member including a 3-1 core and a 3-2 core disposed on opposing surfaces of the 2-1 core and the 2-2 core, respectively, in which the second core member includes a cooling flow path. In the segmented stator core, the cooling performance of a coil is improved.

Description

Technical Field

[0001] The following disclosure relates to a segmented stator core for use in an electric motor, and more particularly, to a stator core design with improved cooling performance. Background Art

[0002] Conventionally, the reduction in weight and size of drive motors has been developed as a way to improve vehicle mileage. Therefore, when the size of a vehicle motor is reduced to increase the power per unit volume of the vehicle motor, the copper loss generated by the coil increases to obtain the same power, and the increase in copper loss generated by the coil leads to an increase in coil temperature, resulting in the problem of insulation damage.

[0003] Therefore, in the prior art, in order to prevent this phenomenon, an attempt is made to cool the heat generated by the coil, and an oil cooling method is used. The prior art oil cooling method attempts to directly cool the stator core or the end coil outside the stator core by spraying a cooling fluid.

[0004] Since the existing direct cooling method focuses on cooling only the end coils exposed to the outside of the stator core, there is a problem that the coil temperature in the stator core slot remains high. In addition, since the temperature sensor that monitors the coil temperature is also attached to the end coil, even if the coil temperature in the slot increases, the controller cannot reflect the increased temperature, so there is still a risk of coil damage. Utility Model Content

[0005] One embodiment of the present disclosure is directed to providing a segmented stator core in which an inner coil of a stator core slot having a temperature increased to a highest temperature is directly cooled in an oil-cooled motor part, thereby improving cooling performance of the coil.

[0006] Another embodiment of the present disclosure is directed to providing a segmented stator core in which power is increased using a higher current density than is currently the case by improving cooling performance of coils inside slots to reduce temperature compared to the same losses.

[0007] Another embodiment of the present disclosure is directed to providing a segmented stator core in which cooling efficiency is maximized by applying a non-uniform shape including a cooling flow path in a portion of the stator core to allow cooling oil to flow from an outer diameter of the stator core into a slot and allow the flowing oil to cool end coils outside the stator core.

[0008] Another embodiment of the present disclosure is directed to providing a segmented stator core in which the number of components is reduced by spraying a cooling fluid to a side of the stator core and allowing the cooling fluid to flow into the stator core through a flow path formed within the stator.

[0009] In one general aspect, a segmented stator core is provided, around which a coil is wound, the segmented stator core comprising: a first core member including a first core, the first core including a first slot, the first slot being a hole into which the coil is inserted; a second core member including a second slot, the second slot being a hole into which the coil is inserted, and the second core member including a 2-1 core and a 2-2 core arranged on both sides of the first core member such that one surface of each of the 2-1 core and the 2-2 core contacts a corresponding side of the first core member; and a third core member including a third slot, the third slot being a hole into which the coil is inserted, and the third core member including a 3-1 core and a 3-2 core arranged on opposing surfaces of the 2-1 core and the 2-2 core, respectively, such that one surface of the 3-1 core and the 3-2 core contacts a corresponding opposing surface of the 2-1 core and the 2-2 core, wherein the second core member includes a cooling flow path extending so as to receive a cooling fluid from the outside and deliver the cooling fluid to an inside of the second slot.

[0010] The outer diameter of the first core component may be smaller than the outer diameters of the second core component and the third core component.

[0011] The second core component may include an outer region that does not contact the first core component, and the cooling flow path may extend through the second core component and include a cooling fluid inlet provided in the outer region and a cooling fluid delivery portion having one end and the other end connected to the cooling fluid inlet and the second groove, respectively.

[0012] The cooling fluid delivery portion may include a first delivery portion communicating with one side of the second groove in a circumferential direction.

[0013] The cooling fluid delivery portion may further include a second delivery portion communicating with the other side of the second groove along the circumferential direction.

[0014] The second groove may be larger in width and height than the first groove and the third groove by a predetermined length.

[0015] The first slot, the second slot and the third slot can be configured so that one end thereof is open toward an opening defined in the center of each of the first core component, the second core component and the third core component, and each of the first core component, the second core component and the third core component can include a stator shoe that protrudes from the one end of the first slot, the second slot and the third slot in a circumferential direction toward the inner side of the first slot, the second slot and the third slot.

[0016] The first, second, and third grooves may be configured such that a circumferential length of an end portion of each of the first, second, and third grooves opposite to the opening is greater than a circumferential length of an end portion adjacent to the opening.

[0017] The stator shoe of the second core member may extend in the circumferential direction to completely block the second slot and the opening from each other.

[0018] The stator shoe of the second core member may have a groove recessed in a radial direction in a circumferential center of the stator shoe.

[0019] The stator shoe may be formed in two or more pieces in the radial direction, extending longer toward the opening in the circumferential direction, and the segmented stator core further includes a support member inserted between the stator shoes.

[0020] The segmented stator core may further include an insulating portion that insulates the coil from the first core component, the second core component, and the third core component, wherein the insulating portion includes a first insulating paper that surrounds an outer surface of the coil; and a second insulating paper that has a surface that contacts the first slot, the second slot, the third slot, and an inner surface of the stator shoe.

[0021] Other features and aspects will be apparent from the following detailed description, drawings, and claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 is an exploded perspective view of a segmented stator core of the present disclosure.

[0023] Figure 2 is a plan view of a first core component of the present disclosure.

[0024] Figure 3 is a plan view of a second core component of the present disclosure.

[0025] Figure 4 is a plan view of a third core component of the present disclosure.

[0026] Figure 5 is an axial cross-sectional view of a segmented stator core of the present disclosure.

[0027] Figure 6 is a partial plan view of a second core component of the present disclosure.

[0028] Figure 7 1 is a partial plan view of a case where a first core component and a second core component of the present disclosure are overlapped with each other.

[0029] Figure 8 is a partial cross-sectional view of an embodiment of an insulation portion of a segmented stator core to which the present disclosure is applied.

[0030] Fig. 9 1 is a partial plan view showing a second core member of the first embodiment of the cooling fluid transporting portion of the present disclosure.

[0031] Fig.10 1 is a partial plan view showing a second core member of a second embodiment of a cooling fluid transporting portion of the present disclosure.

[0032] Fig.11 1 is a partial plan view showing a second core member of the first embodiment of the stator shoe of the present disclosure.

[0033] Fig.12 1 is a partial plan view showing a second core component of a second embodiment of a stator shoe of the present disclosure.

[0034] Fig.13 is a partial plan view showing a third embodiment of a stator shoe of the present disclosure.

[0035] Detailed description of the main components

[0036] 1000: Segmented stator core

[0037] 100: First core component

[0038] 110: First slot

[0039] 200: Second core component

[0040] 210: Second slot

[0041] 220: Cooling flow path

[0042] 221: Cooling fluid inlet

[0043] 222: Cooling fluid delivery unit

[0044] 300: The third core component

[0045] 310: Third slot

[0046] 400: Stator boots

[0047] 500: Support

[0048] 600: Insulation

[0049] 610: The first insulating paper

[0050] 620: Second insulation paper DETAILED DESCRIPTION

[0051] Hereinafter, preferred embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. Before the description, it should be understood that the terms used in the specification and the appended claims should not be interpreted as limited to the general meaning and dictionary meaning, but are interpreted based on the meaning and concept corresponding to the technical aspects of the present disclosure based on the principle that the inventor is allowed to define the terms.

[0052] In the following, reference will be made to Figure 1 The basic configuration of the segmented stator core 1000 of the present disclosure is described.

[0053] like Figure 1 As shown, the segmented stator core 1000 of the present disclosure is a segmented stator core wound with a coil, and the segmented stator core 1000 may include a first core component 100, a second core component 200, and a third core component 300 stacked in an axial direction. In more detail, the first core component 100 may include a first core having a first slot 110, which is a hole for inserting the coil. In addition, the second core component 200 includes a second slot 210, which is a hole for inserting the coil, and the second core component 200 may include a 2-1 core and a 2-2 core, which are arranged so that one surface thereof contacts both sides of the first core component 100. The 2-1 core and the 2-2 core may be provided in plurality, and the number of the 2-1 core and the number of the 2-2 core may be the same. In addition, the 2-1 core and the 2-2 core may be formed to have the same shape.

[0054] In addition, the segmented stator core 1000 of the present disclosure may include a third slot 310, which is a hole for inserting the coil. In addition, the segmented stator core 1000 of the present disclosure may include a 3-1 core and a 3-2 core, which are arranged so that one surface thereof contacts the other surface of each of the 2-1 core and the 2-2 core. The 3-1 core and the 3-2 core may be provided in plurality, and the number of the 3-1 core and the number of the 3-2 core may be the same. In addition, the 3-1 core and the 3-2 core may be formed to have the same shape.

[0055] In addition, the second core member 200 preferably includes a cooling flow path 220 formed to receive a cooling fluid from the outside and to deliver the cooling fluid to the inside of the second slot 210. By allowing the cooling fluid to flow directly into the second slot 210 into which the coil is inserted, a portion of the coil inserted inside the stator core can also be cooled, and cooling efficiency can be improved by allowing the cooling fluid to directly contact the coil.

[0056] In the following, reference will be made to Figures 2 to 7 Detailed features of the first core component 100 , the second core component 200 , and the third core component 300 of the present disclosure are described in more detail.

[0057] like Figure 2As shown, the first core component 100 can be formed in a thin plate shape with an open center. At this time, the first core component 100 may include a single component (i.e., only one first core), or may have a form in which a plurality of first cores are stacked in the axial direction (thickness direction of the plate). Considering the physical properties of the cooling fluid, the total thickness of the first core component 100 may be thicker than the minimum thickness of the flow path through which the cooling fluid can flow smoothly. In addition, the first groove 110 may be formed so that one side of it is open to the opening, and may be formed in a uniform shape and spaced equidistantly from each other in the circumferential direction.

[0058] In addition, if Figure 3 As shown, the second core component 200 (i.e., the 2-1 core and the 2-2 core) can be formed into a thin plate shape with an open center. The second slot 210 can be formed so that one side thereof is open to the opening, and can be formed into a uniform shape and spaced equidistantly from each other in the circumferential direction. In addition, the second slot 210 of the second core component 200 may include a cooling flow path 220 to transport a cooling fluid from the outside to the coil wound in the second slot 210.

[0059] In addition, if Figure 4 As shown, the third core component 300 (ie, the 3-1 core and the 3-2 core) may be formed in a cylindrical shape having an open center. Figure 4 The bottom of the third core component 300 is shown. The thickness of the third core component 300 may be greater than the thickness of the second core component 200 and the total thickness of the first core component 100. In addition, the third grooves 310 may be formed so that one side thereof is open, and may be formed in a uniform shape and spaced equidistantly from each other in the circumferential direction.

[0060] At this time, the first core component 100, the second core component 200, and the third core component 300 may extend outward in the radial direction and may include a bracket having a threaded hole formed at the same position in the axial direction. Therefore, after the first core component 100, the second core component 200, and the third core component 300 are stacked in the axial direction, their positions may be fixed to each other using a fastener or the like.

[0061] In addition, if Figure 5 As shown, the outer diameter of the first core component 100 may be smaller than the outer diameters of the second core component 200 and the third core component 300. However, preferably, the outer diameter lengths of the second core component 200 and the third core component 300 are the same. Therefore, the second core component 200 may include an outer region that does not contact the first core component 100, and the cooling flow path 220 formed in the second core component 200 may include a cooling fluid inlet 221 formed in the above-mentioned outer region. At this time, the cooling fluid inlet 221 may be formed to pass through the second core component 200.

[0062] Furthermore, when the first core part 100 , the second core part 200 , and the third core part 300 are stacked in the axial direction, the first core part 100 is preferably located at a position corresponding to the cooling fluid inlet 221 formed in the housing surrounding the segmented stator core 1000 .

[0063] Through these structural features, in the segmented stator core 1000 of the present disclosure, when the cooling fluid is injected into the position where the first core parts 100 are stacked, the cooling fluid can be gathered in the area surrounded by the outer areas of the first core parts 100 and the second core parts 200, and the gathered cooling fluid can naturally flow into the cooling fluid inlet 221 formed in the second core part 200. Therefore, even if the cooling fluid is injected on the side of the segmented stator core 1000 of the present disclosure, there is an effect that the cooling fluid can directly exchange heat with the coil inserted inside the segmented stator core 1000.

[0064] In addition, if Figure 6 As shown, the cooling flow path 220 formed in the second core component 200 may include a cooling fluid inlet 221, and may further include a cooling fluid delivery portion 222 having one end and the other end connected to the cooling fluid inlet 221 and the second groove 210. The cooling fluid delivery portion 222 may be formed through the second core component 200, and thus, an area surrounded by the cooling fluid delivery portion 222, the first core component 100, and the third core component 300 may be used as a flow path.

[0065] In addition, if Figure 7 As shown, the second groove 210 may be larger than the first groove 110 and the third groove 310 by a predetermined length in width and height. At this time, the second groove 210 and the third groove 310 may be formed to have the same shape. In addition, the first groove 110, the second groove 210 and the third groove 310 may be arranged so that their circumferential centers coincide with each other. That is, the first groove 110 may be formed in the same shape and formed at a corresponding position, and compared with the first groove 110 and the third groove 310, the second groove 210 may have the same gap on both sides in the circumferential direction.

[0066] Therefore, the outside of the second slot 210 may be blocked by the surfaces of the first core member 100 and the third core member 300 and the flow path surrounded by the second slot 210, the coil, the first core member 100, and the third core member 300. Therefore, the cooling fluid delivered from the cooling fluid delivery flow path may flow along the flow path formed on the outside of the second slot 210 and directly contact the coil, thereby more effectively cooling the coil.

[0067] When the height difference (length difference in the radial direction) among the second groove 210, the first groove 110 and the third groove 310 is h' and the width difference (length difference in the circumferential direction) among the second groove 210, the first groove 110 and the third groove 310 is w', considering the thickness of the second core component 200 and the physical properties of the cooling fluid, the lengths of h' and w' can be greater than the minimum flow path thickness allowing the cooling fluid to flow smoothly.

[0068] In the following, reference will be made to Figure 8 The insulating part 600 of the present disclosure is described in more detail.

[0069] like Figure 8 As shown, the segmented stator core 1000 of the present disclosure may also include an insulating portion 600 that insulates the coil from the first core component 100, the second core component 200, and the third core component 300, and the insulating portion 600 may include: a first insulating paper 610 that surrounds the outer surface of the coil; and a second insulating paper 620, one surface of which is in contact with the first slot 110, the second slot 210, the third slot 310 and the inner surface of the stator shoe 400.

[0070] Therefore, as described above, in the insulating part 600, in addition to simple insulation performance, the cooling fluid flowing into the second slot 210 can be prevented from flowing out of the slot due to the second insulating paper 620 and can flow into the inside of the first insulating paper 610, thereby achieving the effect of directly cooling the coil.

[0071] In the following, reference will be made to Fig. 9 and Fig.10 An embodiment of the cooling flow path 220 of the second core component 200 of the present disclosure is described.

[0072] like Fig. 9 As shown, the cooling fluid delivery portion 222 may include a first delivery portion connected to one side of the second slot 210 in the circumferential direction. Therefore, the cooling fluid can flow directly into the gap between the second slot 210 and the first slot 110 / the third slot 310, that is, into the flow path including the second slot 210 and the first core member 100, and the fluid can flow into the coil faster.

[0073] In addition, if Fig.10 As shown, the cooling fluid delivery portion 222 includes not only the above-mentioned first delivery portion, but also a second delivery portion connected to the other side of the second slot 210 in the circumferential direction. At this time, two cooling fluid inlets 221 can also be formed to correspond to the first delivery portion and the second delivery portion, respectively. Therefore, the cooling fluid can flow into both sides of the gap between the second slot 210 and the first slot 110 / the third slot 310, and since the fluid can flow into the coil side faster, the cooling efficiency can be maximized.

[0074] At this time, Figures 9 and 10 In the embodiment of the cooling flow path 220 shown, the first groove 110, the second groove 210, and the third groove 310 may have a circumferential length of the end opposite to the opening, which is greater than the circumferential length of the end adjacent to the opening. That is, the first groove 110, the second groove 210, and the third groove 310 may be formed in a trapezoidal shape. Therefore, when the cooling fluid flowing in through the cooling fluid conveying portion 222 moves toward the opening, the pressure can be increased, thereby guiding the cooling fluid to smoothly penetrate into the interior of the first insulating paper 610.

[0075] In the following, reference will be made to Figures 11 to 13 The stator shoe 400 of the segmented stator core 1000 of the present disclosure and its implementation are described in more detail.

[0076] As described above, the first slot 110, the second slot 210, and the third slot 310 may be formed so that one end thereof is open toward the opening formed at each of the first core member 100, the second core member 200, and the third core member 300. At this time, the first core member 100, the second core member 200, and the third core member 300 may include a stator shoe 400 protruding from one end of the first slot 110, the second slot 210, and the third slot 310 toward the inner side of the first slot 110, the second slot 210, and the third slot 310 in the circumferential direction. In one embodiment, the stator shoe 400 of the second core member 200 may be formed to extend in the circumferential direction to completely block the second slot 210 and the opening. Therefore, the stator shoe 400 may support the pressure of the cooling fluid flowing into the second slot 210 and prevent the cooling fluid flowing into the second slot 210 from leaking.

[0077] At this time, the stator shoe 400 of the second core component 200 may have a groove formed in the radial direction at the circumferential center. More specifically, as Fig.11 As shown, in the first embodiment of the stator shoe 400, a groove may be formed on one surface of the stator shoe 400, and one surface of the stator shoe 400 may be a surface opposite to the second slot 210. Therefore, the stator shoe 400 may support the pressure of the cooling fluid flowing into the second slot 210.

[0078] Alternatively, if Fig.12As shown, in the second embodiment of the stator shoe 400, grooves may be formed on both sides of the stator shoe 400. That is, grooves may be formed on the surface of the stator shoe 400 facing the second slot 210 and the opposite surface thereof. Therefore, the stator shoe 400 may support the pressure of the cooling fluid flowing into the second slot 210, and further, when the hydraulic pressure of the cooling fluid flowing into the second slot 210 exceeds a certain level, a part of the cooling fluid may flow into the grooves located on the surface of the stator shoe 400 facing the second slot 210, and a part of the cooling fluid may flow out in the axial direction, thereby slightly adjusting the hydraulic pressure in the second slot 210.

[0079] In addition, if Fig.13 As shown, in the third embodiment of the stator shoe 400, the stator shoe 400 may be formed as two or more pieces in the radial direction and extend longer toward the opening in the circumferential direction. At this time, preferably, the segmented stator core 1000 of the present disclosure further includes a support member 500 inserted between the stator shoes 400. The support member 500 may be formed of an insulating material. By including the support member 500 coupled to the stator shoe 400, stability may be increased by preventing vibration of the stator shoe 400 when the motor is driven, and in the case of the second slot 210, the support member 500 may support the pressure of the cooling fluid flowing into the second slot 210. In addition, by including the support member 500, leakage of the cooling fluid flowing into the second slot 210 may be prevented.

[0080] In the segmented stator core of the present disclosure having the above-described configuration, the coils inside the slots having a higher temperature than the end coils are cooled, thereby reducing the risk of damaging the insulation portion.

[0081] Furthermore, since both the end coils and the slot internal coils can be cooled, the load is small even when a large current is applied, thereby increasing the power of the same motor size or reducing the motor size based on the same power.

[0082] Furthermore, because cooling can be performed without separate components such as cooling tubes that spray cooling oil onto the coils, material costs can be reduced and part of the manufacturing process can be eliminated.

[0083] The present disclosure should not be construed as being limited to the above exemplary embodiments. The present disclosure can be applied to various fields and can be variously modified by those skilled in the art without departing from the scope of the present disclosure. Therefore, it is obvious to those skilled in the art that these changes and modifications fall within the scope of the present disclosure.

Claims

1. A segmented stator core, a coil is wound around the segmented stator core, characterized in that: The segmented stator core comprises: A first core member including a first core, wherein the first core includes a first slot, the first slot being a hole into which the coil is inserted; a second core member including a second slot which is a hole into which the coil is inserted, and including a 2-1 core and a 2-2 core arranged on both sides of the first core member such that one surface of each of the 2-1 core and the 2-2 core contacts a corresponding side of the first core member; and a third core component, the third core component including a third slot which is a hole into which the coil is inserted, and the third core component including a 3-1 core and a 3-2 core respectively arranged on opposite surfaces of the 2-1 core and the 2-2 core so that one surface of the 3-1 core and the 3-2 core contacts the corresponding opposite surfaces of the 2-1 core and the 2-2 core, wherein the second core member includes a cooling flow path extending to receive a cooling fluid from the outside and to deliver the cooling fluid to the inside of the second slot.

2. The segmented stator core according to claim 1, characterized in that The outer diameter of the first core member is smaller than the outer diameter of the second core member and the outer diameter of the third core member.

3. The segmented stator core according to claim 2, characterized in that The second core component includes an outer region that does not contact the first core component, and The cooling flow path extends through the second core member and includes a cooling fluid inlet provided in the outer region and a cooling fluid delivery portion having one end and the other end connected to the cooling fluid inlet and the second groove, respectively.

4. The segmented stator core according to claim 3, characterized in that The cooling fluid delivery portion includes a first delivery portion communicating with one side of the second groove along a circumferential direction.

5. The segmented stator core according to claim 4, characterized in that The cooling fluid delivery portion further includes a second delivery portion communicating with the other side of the second groove along the circumferential direction.

6. The segmented stator core according to claim 3, characterized in that The second groove is larger in width and height than the first groove and the third groove by a predetermined length.

7. The segmented stator core according to claim 1, characterized in that The first groove, the second groove, and the third groove are configured such that one ends thereof are open toward an opening defined in the center of each of the first core member, the second core member, and the third core member, and Each of the first, second, and third core members includes a stator shoe that protrudes from the one ends of the first, second, and third slots toward the inside of the first, second, and third slots in a circumferential direction.

8. The segmented stator core according to claim 7, characterized in that The first groove, the second groove, and the third groove are configured such that a circumferential length of an end portion of each of the first groove, the second groove, and the third groove opposite to the opening is greater than a circumferential length of an end portion adjacent to the opening.

9. The segmented stator core according to claim 7, characterized in that The stator shoe of the second core member extends in the circumferential direction to completely block the second slot and the opening from each other.

10. The segmented stator core according to claim 7, characterized in that The stator shoe of the second core member has a groove recessed in a radial direction at a circumferential center of the stator shoe.

11. The segmented stator core according to claim 7, characterized in that The stator shoe is formed in two or more pieces in the radial direction, extends longer toward the opening in the circumferential direction, and the segmented stator core further includes a support member inserted between the stator shoes.

12. The segmented stator core according to claim 1, characterized in that The segmented stator core further comprises: an insulating portion that insulates the coil from the first core member, the second core member, and the third core member, The insulating part includes: a first insulating paper surrounding the outer surface of the coil; and a second insulating paper having a surface in contact with the first slot, the second slot, the third slot and the inner surface of the stator shoe.

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