Coil assembly and motor

Abstract

The utility model discloses a coil assembly and a motor, the coil assembly is used for the motor, and the coil assembly comprises a coil main body and an insulating coating layer. The coil body comprises a wrapping wire and a first insulating layer, and the wrapping wire is wound to form a multi-layer nested annular coil. And a first insulating layer is arranged between two adjacent layers of annular coils. The insulating coating layer is coated on the surface of the coil main body. The problem that after the thickness of the insulating layer of the wrapping wire is reduced, the insulating performance between two adjacent layers of wrapping wires is prone to being poor is solved.

Description

Technical Field

[0001] The present application relates to the field of motor technology, and in particular to a coil assembly and a motor. Background Art

[0002] The thickness of the insulation layer of the wrapped wire is closely related to the voltage level that the wrapped wire can withstand. For AC high-voltage motors, the wrapped wire is under high voltage. In order to ensure good electrical insulation performance, the wrapped wire needs to use a thicker insulation layer. However, the thicker insulation layer occupies more space in the stator slot of the motor, resulting in a reduction in the space occupied by the flat copper wire in the stator slot. This will cause the ratio of the cross-sectional area occupied by the flat copper wire in the stator slot to the total amount of available space in the bare slot to decrease, that is, the slot fill rate of the motor will decrease, which will affect the working efficiency of the motor. In addition, the use of a thicker insulation layer will also increase the volume of the wrapped wire, which will increase the manufacturing cost.

[0003] In the prior art, in order to improve the slot fill rate of the motor, the insulation layer of the wrapped wire can be thinned by reducing the thickness of the insulation layer of the wrapped wire without changing the voltage of the motor and the cross-sectional area of ​​the flat copper wire, thereby reducing the space occupied by the insulation layer of the wrapped wire in the stator slot, thereby improving the slot fill rate of the motor. However, the insulation performance of the insulation layer of the thinned wrapped wire is poor, and short circuits and insulation breakdown are prone to occur between two adjacent layers of wrapped wires. Utility Model Content

[0004] The main purpose of the present application is to provide a coil assembly to solve the problem mentioned in the background art that after the thickness of the insulation layer of the wrapped wire is reduced, the insulation performance between two adjacent layers of the wrapped wire is poor.

[0005] According to one aspect of the present application, a coil assembly is provided, the coil assembly being used for a motor, the coil assembly comprising:

[0006] A coil body, the coil body comprising a wrapped conductor and a first insulating layer, the wrapped conductor is wound to form a multi-layer nested annular coil, and the first insulating layer is arranged between two adjacent layers of the annular coil;

[0007] An insulating coating layer is coated on a surface of the coil body.

[0008] Furthermore, along a first direction (specifically, a width direction of the coil assembly), a width of the first insulating layer is not less than a width of the wrapped conductor.

[0009] Furthermore, along the first direction, two opposite ends of the first insulating layer are both in contact with the insulating coating layer.

[0010] Furthermore, along the second direction (specifically, the length direction of the coil assembly), the thickness of the first insulating layer is between 0.05 mm and 0.12 mm.

[0011] Furthermore, the wrapped conductor includes a core, and along a first direction, the core has a first width, and the coil assembly has a second width, and a difference between the second width and the first width is no more than 1.1 mm.

[0012] Furthermore, the wrapped conductor also includes a second insulating layer, the second insulating layer is wrapped around the surface of the wire core, and the wire core includes a flat wire.

[0013] Furthermore, the maximum thickness of the second insulating layer is not greater than 0.15 mm.

[0014] Furthermore, the first insulating layer includes at least one of an aromatic polyamide paper strip and an alkali-free glass fiber tape.

[0015] Furthermore, the insulating coating layer comprises:

[0016] Mica tape, the mica tape is wrapped around the surface of the coil body;

[0017] An anti-corona tape is wrapped around the surface of the mica tape facing away from the coil body.

[0018] On the other hand, the present application further provides a motor, comprising a stator slot, wherein the coil assembly described in the above technical solution is arranged in the stator slot.

[0019] In the present application, the coil body of the provided coil assembly includes a wrapped conductor and a first insulating layer. On the basis of thinning the insulation thickness of the wrapped conductor, the first insulating layer can be provided between two adjacent layers of annular coils of the coil body to effectively isolate the two adjacent layers of annular coils, thereby improving the insulation performance between the two adjacent layers of annular coils. Therefore, the present application provides a first insulating layer between two layers of annular coils, which can not only improve the slot filling rate of the motor using the coil assembly, but also effectively reduce the risk of short circuit, insulation breakdown, etc. between the two adjacent layers of annular coils, which is beneficial to ensure that the electrical conductivity of the coil assembly is good under high voltage conditions, and is also beneficial to ensure that the insulation performance of the motor is safe and reliable during operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The drawings described herein are used to provide a further understanding of the present application and constitute a part of the present application. The illustrative embodiments of the present application and their descriptions are used to explain the present application and do not constitute an improper limitation on the present application. In the drawings:

[0021] Figure 1 A schematic diagram of a coil assembly disclosed in the present application;

[0022] Figure 2 It is a cross-sectional schematic diagram of the coil assembly at AA;

[0023] Figure 3 for Figure 1 The enlarged view of P in the middle;

[0024] The above drawings include the following reference numerals:

[0025] 1. Coil body; 11. Wrapped conductor; 111. Wire core; 112. Second insulating layer; 12. First insulating layer; 2. Insulating coating layer; 21. Mica tape; 22. Anti-corona tape. DETAILED DESCRIPTION

[0026] It should be noted that, in the absence of conflict, the embodiments and features in the embodiments of the present application can be combined with each other. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0027] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, it indicates the presence of features, steps, operations, devices, components and / or combinations thereof.

[0028] Unless otherwise specifically stated, the relative arrangement, numerical expressions and numerical values ​​of the parts and steps set forth in these embodiments do not limit the scope of the present application. At the same time, it should be understood that, for ease of description, the sizes of the various parts shown in the accompanying drawings are not drawn according to the actual proportional relationship. The technology, methods and equipment known to those of ordinary skill in the relevant art may not be discussed in detail, but in appropriate cases, the technology, methods and equipment should be considered as a part of the authorization specification. In all examples shown and discussed here, any specific value should be interpreted as being merely exemplary, rather than as a limitation. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters represent similar items in the following drawings, and therefore, once a certain item is defined in an accompanying drawing, it does not need to be further discussed in subsequent drawings.

[0029] In order to improve the slot fill rate of the motor, the prior art thins the wrapped wire by reducing the thickness of the insulation layer of the wrapped wire without changing the voltage of the motor and the cross-sectional area of ​​the flat copper wire. Since the insulation performance of the insulation layer of the thinned wrapped wire is poor, short circuits and insulation breakdown are likely to occur between two adjacent layers of wrapped wires. In response to this problem, the first embodiment of the utility model provides a coil assembly, see Figures 1 to 3 .

[0030] A coil assembly is used for a motor. The coil assembly includes a coil body 1 and an insulating coating layer 2. The coil body 1 includes a wrapped conductor 11 and a first insulating layer 12. The wrapped conductor 11 is wound to form a multi-layer nested annular coil. A first insulating layer 12 is provided between two adjacent layers of annular coils. The insulating coating layer 2 is coated on the surface of the coil body 1.

[0031] In this embodiment, the first insulating layer 12 provided between two adjacent layers of annular coils can effectively isolate the two adjacent layers of annular coils, thereby improving the insulation performance between the two adjacent layers of annular coils. Therefore, the first insulating layer 12 can effectively reduce the occurrence of short circuits, insulation breakdown and the like between the two adjacent layers of annular coils, which is beneficial to ensuring that the electrical conductivity of the coil assembly is good under high voltage conditions, and is also beneficial to ensuring that the insulation performance of the motor is safe and reliable during operation. In addition, the insulating coating layer component can cover and fix the coil body 1 to improve the structural stability and strength of the coil body 1, and can also insulate the coil body 1 from the inner wall of the stator slot, which can prevent short circuits or insulation breakdown between the coil assembly and the inner wall of the stator slot, and is beneficial to improving the safety and reliability of the motor.

[0032] It can be seen that the coil body 1 of the coil assembly provided in this embodiment includes a wrapped conductor 11 and a first insulating layer 12. On the basis of thinning the wrapped insulation thickness of the wrapped conductor 11, the first insulating layer 12 can be provided between two adjacent layers of annular coils of the coil body 1 to effectively isolate the two adjacent layers of annular coils, thereby improving the insulation performance between the two adjacent layers of annular coils. Therefore, the first insulating layer 12 is provided between the two layers of annular coils in this application, which can not only improve the slot filling rate of the motor using the coil assembly, but also effectively reduce the risk of short circuit, insulation breakdown and the like between the two adjacent layers of annular coils, which is beneficial to ensure that the electrical conductivity of the coil assembly is good under high voltage conditions, and is also beneficial to ensure that the insulation performance of the motor is safe and reliable during operation.

[0033] In order to ensure that the first insulating layer 12 can effectively isolate the two adjacent layers of annular coils. Figure 2The direction indicated by the arrow B shown is specifically the width direction of the coil assembly), and the width L1 of the first insulating layer is not less than the width L2 of the wrapped conductor. The width L1 of the first insulating layer is not less than the width L2 of the wrapped conductor, which can ensure that the first insulating layer 12 completely isolates the two adjacent layers of annular coils, ensures that the current cannot flow between the two adjacent layers of annular coils, and reduces the occurrence of short circuits and insulation breakdown between the two adjacent layers of annular coils. It is beneficial to extend the service life of the wrapped conductor 11 and reduce the maintenance cost of the coil assembly. If the width L1 of the first insulating layer is less than the width L2 of the wrapped conductor, it is easy to cause insulation failure and short circuit between the two adjacent layers of annular coils, posing a major safety hazard.

[0034] There are many ways to set the first insulating layer 12. For example, the first insulating layer 12 can be overlapped with the wrapped conductor 11 and then wound into multiple layers with the wrapped conductor 11 to form a toroidal coil. Alternatively, the wrapped conductor 11 can be wound into multiple layers of toroidal coils and then the first insulating layer 12 can be placed between two adjacent layers of toroidal coils. It can be understood that the specific setting method of the first insulating layer 12 can be adjusted according to actual needs, and this embodiment does not make a sole limitation.

[0035] In order to further ensure that the insulation performance of the first insulating layer 12 is good, and the stability of the first insulating layer 12 is good. In one embodiment, along the first direction, the opposite ends of the first insulating layer 12 are both in contact with the insulating coating 2. The first insulating layer 12 and the insulating coating 2 can wrap the wrapped conductor 11, further isolate the two adjacent layers of annular coils, and completely isolate the two adjacent layers of annular coils, and further avoid short circuits or insulation punctures between the annular coils. In addition, in this embodiment, the opposite ends of the first insulating layer 12 are in contact with the insulating coating 2, so that the first insulating layer 12 is not easy to deviate relative to the insulating coating 2, so as to limit the first insulating layer 12 to the current position, ensure that the first insulating layer 12 will not deviate due to motor operation vibration and other reasons, ensure the stability of the first insulating layer 12, and then improve the insulation stability of the first insulating layer 12 to the wrapped conductor.

[0036] In one embodiment, the wrapped conductor 11 includes a core 111. Along the first direction, the core 111 has a first width H1, and the coil assembly has a second width H2, where the second width H2 is the width of the coil body 1 and the thickness of the insulating coating on the opposite sides of the coil body 1 along the first direction. The difference between the second width H2 and the first width H1 is not greater than 1.1 mm. For example, the difference between the second width H2 and the first width H1 can be set to one of 0.9 mm, 0.95 mm, 1.0 mm, 1.1 mm, etc. Setting the difference between the second width H2 and the first width H1 to be no greater than 1.1 mm is conducive to reducing the thickness of the insulating layer of the coil assembly. After the thickness of the insulating layer of the coil assembly is reduced, the space occupied by the insulating layer of the coil assembly in the stator slot of the motor is also reduced accordingly. Under the premise of not changing the motor voltage and the cross-sectional area of ​​the core 111, the slot fill rate of the motor will be increased accordingly. Since the slot fill rate of the motor is improved and the arrangement density of the core 111 is improved, it is beneficial to enhance the magnetic flux of the core 111, and the motor can more effectively utilize the magnetic field energy during operation, thereby improving the power and efficiency of the motor. Therefore, the difference between the second width H2 and the first width H1 is not greater than 1.1 mm, which is beneficial to improve the slot fill rate of the motor and thus improve the working efficiency of the motor. The volume of the coil assembly is reduced, which is convenient for installing more coil assemblies in the motor slot and is also beneficial to reducing the manufacturing cost of the motor. If the difference between the second width H2 and the first width H1 is greater than 1.1 mm, the thickness of the insulating layer of the coil assembly will be too large, which will reduce the slot fill rate of the motor and the working efficiency of the motor.

[0037] like Figure 3 As shown, in one embodiment, along the second direction (such as Figure 2 The direction indicated by the arrow C shown is specifically the length direction of the coil assembly), and the thickness D1 of the first insulating layer 12 is between 0.05 mm and 0.12 mm. For example, the thickness D1 of the first insulating layer 12 can be set to one of 0.05 mm, 0.06 mm, 0.07 mm, 0.08 mm, 0.09 mm, 0.10 mm, 0.11 mm, 0.12 mm, etc. The thickness D1 of the first insulating layer 12 is between 0.05 mm and 0.12 mm, so that the first insulating layer 12 can have sufficient insulation strength to ensure that the first insulating layer 12 is not easily broken down, and further ensure that the two adjacent layers of annular coils are effectively isolated by the first insulating layer 12, so that the insulation between the two adjacent layers of annular coils is better, and ensure that the first insulating layer 12 is not easily broken down. If the thickness D1 of the first insulating layer 12 is less than 0.05 mm, the thickness D1 of the first insulating layer 12 is too small, the first insulating layer 12 cannot provide sufficient insulation strength, the first insulating layer 12 is easily broken down, and short circuits and open circuits are easily caused between the wound coils, affecting the insulation performance of the coil body 1 and also affecting the normal operation of the motor.

[0038] In order to further improve the slot fill rate of the motor. In one embodiment, the wrapped conductor 11 also includes a second insulating layer 112, and the second insulating layer 112 is wrapped around the surface of the core 111, and the core 111 includes a flat conductor. Compared with the core 111 of other shapes such as round and elliptical, the flat conductors are more closely in contact with each other, and the gaps between the flat conductors are smaller, which is conducive to improving the slot fill rate of the motor and ensuring higher working efficiency of the motor. In addition, the cross-sectional area of ​​the flat conductor is small, which is convenient for bending to form the required molded coil structure. The flat conductor can also better fit with the first insulating layer 12, thereby improving the insulation performance between the adjacent two side ring coils.

[0039] In one embodiment, the maximum thickness D2 of the second insulating layer 112 is not greater than 0.15 mm. The thickness of the second insulating layer 112 specifically includes the thickness along the first direction and the thickness along the second direction. When the thickness of the second insulating layer in the first direction is greater than the thickness of the second insulating layer in the second direction, the maximum thickness D2 of the second insulating layer 112 is the thickness in the first direction. Conversely, when the thickness of the second insulating layer in the second direction is greater than the thickness of the second insulating layer in the first direction, the maximum thickness D2 of the second insulating layer 112 is the thickness in the second direction. Specifically, the maximum thickness D2 of the second insulating layer 112 can be set to one of 0.11 mm, 0.12 mm, 0.125 mm, 0.13 mm, 0.14 mm, 0.15 mm, etc. The maximum thickness D2 of the second insulating layer 112 is not greater than 0.15 mm, so that the thickness D2 of the second insulating layer 112 will not be too large, which is conducive to reducing the thickness of the insulating layer of the coil assembly, improving the slot full rate of the motor, and reducing the volume of the wrapped coil and reducing the production cost of the wrapped coil. If the maximum thickness D2 of the second insulating layer 112 is greater than 0.15 mm, the maximum thickness D2 of the second insulating layer 112 is too large, resulting in a larger thickness of the insulating layer of the coil body 1, which may easily lead to a decrease in the slot fill rate of the motor, which is not conducive to efficient operation of the motor.

[0040] For example, the conventional 0.25 mm thick second insulating layer 112 is thinned to a 0.125 mm thick second insulating layer 112.

[0041] Accordingly, the width of the coil assembly is reduced by 0.25 mm, and the difference between the second width H2 and the first width H1 is reduced from 1.25 mm to 1.00 mm, thereby reducing the thickness of the insulating layer of the coil assembly and improving the slot fill rate of the motor.

[0042] In one embodiment, the first insulating layer 12 includes at least one of an aromatic polyamide paper strip and an alkali-free glass fiber tape. When the first insulating layer 12 is made of an aromatic polyamide paper strip, the aromatic polyamide paper strip has excellent heat resistance. Even when the temperature exceeds 220°C, the stability of the aromatic polyamide paper strip is still good, ensuring that the first insulating layer 12 is used in a high temperature and high voltage operating environment of the motor. The aromatic polyamide paper strip also has good electrical insulation performance, which can effectively isolate two adjacent layers of annular coils, prevent current from flowing between the annular coils, and ensure that the electrical insulation performance of the coil assembly is good.

[0043] When the first insulating layer 12 is made of alkali-free glass fiber tape, the alkali-free glass fiber tape has an extremely low thermal conductivity, can effectively isolate high temperature transfer, and can provide a good thermal insulation effect between two adjacent layers of annular coils to ensure the stability of the annular coils. The alkali-free glass fiber tape can also provide a stable support and insulation effect, effectively isolating adjacent annular coils. At the same time, it ensures that the insulation between the annular coils is good.

[0044] In one embodiment, the insulating coating layer includes mica tape 21, and the mica tape 21 is wrapped around the surface of the coil body 1. The mica tape 21 is a high-performance insulating material that can provide a safe insulating barrier to prevent short circuit or insulation breakdown between the coil assembly and the inner wall of the stator slot, and to prevent operators from suffering electric shock due to contact with live parts. Specifically, the mica tape 21 can be set to one or more of glass cloth reinforced mica tape 21 with less rubber powder and film reinforced mica tape 21 with less rubber powder.

[0045] In one embodiment, the insulating coating layer also includes an anti-corona tape 22, and the anti-corona tape 22 is wrapped around the surface of the mica tape 21 away from the coil body 1. The anti-corona tape 22 can balance the potential, reduce the potential on the surface of the coil assembly and the potential of the motor core, thereby avoiding the air near the coil assembly from being ionized, preventing the electromagnetic field of the motor from being disordered, ensuring the stability and safety of electromagnetic transmission, and helping to improve the service life of the motor. The anti-corona tape 22 can also withstand the influence of stress factors such as impulse voltage repetition rate, fundamental frequency peak-to-peak voltage, sudden voltage, impulse rise time and number of levels, effectively reducing the occurrence of overheating and degradation of the anti-corona layer after long-term operation of the motor, and preventing the temperature of the coil assembly from being too high and affecting the operation of the motor. The anti-corona tape 22 may specifically include a low-resistance anti-corona tape.

[0046] The mica tape 21 and the anti-corona tape 22 may be provided separately or simultaneously, which is not limited in this embodiment.

[0047] On the other hand, the second embodiment of the utility model further provides a motor, the motor includes a stator slot, and the stator slot is provided with the coil assembly provided by the first embodiment of the utility model, so the motor includes all the technical effects of the above coil assembly. Since the first embodiment has described the technical effects of the coil assembly in detail, this embodiment will not repeat them.

[0048] For ease of description, spatially relative terms such as "above", "above", "on the upper surface of", "above", etc. may be used here to describe the spatial positional relationship between a device or feature and other devices or features as shown in the figure. It should be understood that spatially relative terms are intended to include different orientations of the device in use or operation in addition to the orientation described in the figure. For example, if the device in the accompanying drawings is inverted, the device described as "above other devices or structures" or "above other devices or structures" will be positioned as "below other devices or structures" or "below other devices or structures". Thus, the exemplary term "above" can include both "above" and "below". The device can also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatially relative descriptions used here are interpreted accordingly.

[0049] In addition, it should be noted that the use of terms such as "first" and "second" to limit components is only for the convenience of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore cannot be understood as limiting the scope of protection of this application.

[0050] The above are only preferred embodiments of the present application and are not intended to limit the present application. For those skilled in the art, the present application may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A coil assembly, the coil assembly being used for a motor, characterized in that: The coil assembly comprises: A coil body (1), the coil body (1) comprising a wrapped conductor (11) and a first insulating layer (12), the wrapped conductor (11) being wound to form a multi-layer nested annular coil, the first insulating layer (12) being arranged between two adjacent layers of the annular coil; An insulating coating layer (2), wherein the insulating coating layer (2) is coated on the surface of the coil body (1).

2. A coil assembly according to claim 1, characterized in that: Along the first direction, the width of the first insulating layer (12) is not less than the width of the wrapped conductor (11).

3. A coil assembly according to claim 2, characterized in that: Along a first direction, opposite ends of the first insulating layer (12) are both in contact with the insulating coating layer (2).

4. The coil assembly according to claim 1, characterized in that: Along the second direction, the thickness of the first insulating layer (12) is between 0.05 mm and 0.12 mm.

5. The coil assembly according to claim 1, characterized in that: The wrapped conductor (11) comprises a wire core (111), and along a first direction, the wire core (111) has a first width, and the coil assembly has a second width, and the difference between the second width and the first width is no more than 1.1 mm.

6. The coil assembly according to claim 5, characterized in that: The wrapped conductor (11) further comprises a second insulating layer (112), wherein the second insulating layer (112) is wrapped around the surface of the wire core (111), and the wire core (111) comprises a flat wire.

7. The coil assembly according to claim 6, characterized in that: The maximum thickness of the second insulating layer (112) is no greater than 0.15 mm.

8. The coil assembly according to claim 1, characterized in that: The first insulating layer (12) comprises at least one of an aromatic polyamide paper strip and an alkali-free glass fiber tape.

9. The coil assembly according to claim 1, characterized in that: The insulating coating layer comprises: A mica tape (21), wherein the mica tape (21) is wrapped around the surface of the coil body (1); And / or, an anti-corona tape (22), wherein the anti-corona tape (22) is wrapped around a surface of the mica tape (21) facing away from the coil body (1).

10. A motor, characterized in that: The motor comprises a stator slot, in which the coil assembly according to any one of claims 1 to 9 is arranged.

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