Busbar assembly

Abstract

The utility model provides a busbar assembly. The busbar assembly is suitable for a motor stator, the motor stator comprises a stator iron core and a plurality of flat wire windings, and the busbar assembly is arranged at one end of the motor stator and connected with the plurality of flat wire windings. The busbar assembly comprises a first phase busbar, a second phase busbar, a third phase busbar, at least one neutral line busbar and a base. The base comprises a first insulating layer body and a second insulating layer body, wherein the second insulating layer body is arranged on the first insulating layer body and connected with the first insulating layer body. The first phase busbar and the second phase busbar are at least partially arranged on the first insulating layer body, and the third busbar and the at least one neutral line busbar are fixedly arranged on the upper surface of the second insulating layer body. Therefore, the effects of reducing the size of the assembly, reducing the material cost, simplifying and facilitating the assembly operation and improving the electrical safety can be achieved.

Description

TECHNICAL FIELD

[0001] The utility model relates to a busbar assembly, especially a busbar assembly suitable for a motor stator. BACKGROUND

[0002] With the breakthrough of electric vehicle technology, the electric vehicle has reached a certain market size. In order to be more widely configured in various vehicle bodies and applied in different performance vehicle models, the drive system in the electric vehicle needs to reduce the size and improve the power density, which is the index of market competition. Since the hair-pin flat wire winding is arranged in the corresponding slot of the stator core to improve the slot fill rate, the flat wire motor has high power density and operation efficiency, and becomes the mainstream of the electric vehicle motor.

[0003] In the flat wire motor, the outgoing wires of different phases in the flat wire winding are integrated through the busbar assembly arranged at one end of the motor stator, and then the external wires (such as the wires of the inverter and / or the battery) are connected through the busbar assembly for power supply, so as to drive the motor to act. However, the busbar assembly in the prior art has a large number of components with complex shapes, and the components are not properly arranged in space. Not only the size of the busbar assembly is large, which increases the overall volume of the motor, but also the material cost is high, the assembly process is complicated, which is not conducive to manufacturing and assembly, resulting in increased production cost and limited industrial application.

[0004] Therefore, it is necessary to provide a busbar assembly suitable for a motor stator to solve the defects of the prior art. SUMMARY

[0005] The utility model discloses a busbar assembly suitable for a motor stator, which comprises a first-phase busbar, a second-phase busbar, a third-phase busbar, at least one neutral busbar and a base. Through the structural profile design of the above-mentioned elements and the arrangement in space, the size of the busbar assembly can be reduced, the material cost can be reduced, the assembly operation can be simplified and facilitated, and the electrical safety can be improved.

[0006] Another object of the utility model is to provide a busbar assembly suitable for a motor stator. The first insulating layer and the second insulating layer of the base are designed as a one-piece structure or a combined structure that can be mutually connected. The first-phase busbar and the second-phase busbar are arranged on the first insulating layer, and the third-phase busbar and the at least one neutral busbar are arranged on the second insulating layer. The above-mentioned elements are separated from each other, which can improve the electrical safety of the busbar assembly, reduce the size of the busbar assembly, and simplify and facilitate the assembly operation.

[0007] To achieve the foregoing purpose, the utility model provides a busbar assembly suitable for motor stator. Motor stator includes stator core and multiple flat wire windings, multiple flat wire windings are around stator core, and multiple flat wire windings include first phase winding, second phase winding, third phase winding and at least one neutral line winding. Busbar assembly is arranged at one end of motor stator. Busbar assembly includes first phase busbar, second phase busbar, third phase busbar, at least one neutral line busbar and base. First phase busbar includes first body, first wiring part and at least one first contact part, wherein first wiring part and at least one first contact part extend outward from at least one side of first body, and first contact part is structured to be connected with first phase winding. Second phase busbar includes second body, second wiring part and at least one second contact part, wherein second wiring part and at least one second contact part extend outward from at least one side of second body, and second contact part is structured to be connected with second phase winding. Third phase busbar includes third body, third wiring part and at least one third contact part, wherein third wiring part and at least one third contact part extend outward from one side of third body, and third contact part is structured to be connected with third phase winding. At least one neutral line busbar includes fourth body and at least one fourth contact part, wherein at least one fourth contact part extends outward from one side of fourth body, and fourth contact part is structured to be connected with at least one neutral line winding. Base includes first side, second side, first insulating layer and second insulating layer, wherein second insulating layer is arranged on first insulating layer and connected with each other, and first side and second side are opposite. First body of first phase busbar and second body of second phase busbar are arranged at least partially on first insulating layer and separated from each other, first wiring part is exposed from first side of base and arranged to extend in a first direction, second wiring part is exposed from second side of base and arranged to extend in the first direction, at least one first contact part and at least one second contact part are exposed from at least one of first side and second side of base and arranged to extend in the first direction. Third phase busbar and at least one neutral line busbar are arranged on an upper surface of second insulating layer and separated from each other, third wiring part is arranged on the upper surface of second insulating layer and extends in the first direction, at least one third contact part and at least one fourth contact part are arranged on the upper surface of second insulating layer and extend in the first direction.

[0008] According to one embodiment of the utility model, the base is a single-piece structure formed integrally, and the base is formed by overmolding, such that the base at least partially covers the first phase busbar and the second phase busbar, and the third phase busbar and the at least one neutral line busbar are at least partially embedded in the base, so that the third phase busbar and the at least one neutral line busbar are fixedly arranged in the base.

[0009] According to one of the embodiments of the present application, the first insulation layer body comprises a plurality of first installation grooves arranged on an upper surface of the first insulation layer body for positioning and assembling the first body of the first busbar and the second body of the second busbar.

[0010] According to one of the embodiments of the present application, the first insulation layer body comprises at least one protrusion, each of the protrusions is connected with a corresponding first installation groove, wherein the first busbar and the second busbar each comprise at least one recess, and the at least one recess is correspondingly assembled and engaged with the at least one protrusion.

[0011] According to one of the embodiments of the present application, the second insulation layer body comprises a plurality of second installation grooves arranged on the upper surface of the second insulation layer body for positioning and assembling the third busbar and the at least one neutral busbar.

[0012] According to one of the embodiments of the present application, the second insulation layer body comprises a sensor accommodating seat arranged on the upper surface of the second insulation layer body for accommodating a temperature sensor.

[0013] According to one of the embodiments of the present application, the second insulation layer body comprises a lower surface, and the lower surface is tightly attached to the first body of the first busbar and the second body of the second busbar.

[0014] According to one of the embodiments of the present application, the third wiring part of the third busbar is arranged between the first side edge and the second side edge of the base, and the upper surface of the base is located in a plane formed by a second direction and a third direction, wherein the first direction, the second direction and the third direction are perpendicular to each other.

[0015] According to one of the embodiments of the present application, the first contact part comprises a first contact part terminal, the second contact part comprises a second contact part terminal, the third contact part comprises a third contact part terminal, the fourth contact part comprises a fourth contact part terminal, and the first contact part terminal and the second contact part terminal are lower than the third contact part terminal and the fourth contact part terminal in the first direction.

[0016] According to one of the embodiments of the present application, the first insulation layer body comprises at least one first fastener, the at least one first fastener is adjacent to at least one of the first side edge and the second side edge of the base, and the first insulation layer body is connected and combined with the second insulation layer body by the at least one first fastener of the first insulation layer body fastened to a corresponding side edge of the second insulation layer body.

[0017] According to one of the embodiments of the utility model, the second insulation layer body comprises at least one second fastener, the at least one second fastener is adjacent to at least one of the first side edge and the second side edge of the base, the side edge of the third phase busbar and the at least one neutral line busbar is buckled by the at least one second fastener of the second insulation layer body, so that the third phase busbar and the at least one neutral line busbar are fixed on the upper surface of the second insulation layer body.

[0018] According to one of the embodiments of the utility model, the first phase busbar is a U phase busbar, the second phase busbar is a W phase busbar, the third phase busbar is a V phase busbar, and the neutral line busbar is a Y connection busbar.

[0019] The utility model discloses a kind of busbar assemblies suitable for motor stator, by the structural contour design of each busbar and base and arrangement and configuration in space, can reach the size of busbar assembly, reduce material cost, simplify and facilitate assembly operation and promote electrical safety efficiency.This further, through the single-piece structure design of the first insulation layer body and the second insulation layer body of base is integrally formed, or the combination structure design of the first insulation layer body and the second insulation layer body is mutually clamped, first phase busbar and second phase busbar can be arranged in the first insulation layer body, third phase busbar and at least one neutral line busbar are arranged in the second insulation layer body, and the above-mentioned elements are separated from each other, so that the electrical safety of busbar assembly can be improved, the size of busbar assembly is reduced, and assembly operation is simplified and facilitated.In addition, the base of busbar assembly includes sensor setting seat, temperature sensor can be arranged, which helps the installation of temperature sensor, and is beneficial to the temperature detection of motor stator by temperature sensor. BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1A It is structural schematic view that the busbar assembly of the utility model is applied to a motor stator.

[0021] Figure 1B It is structural schematic view that the busbar assembly of the utility model is applied to a motor stator in another perspective.

[0022] Figure 2A It is structural schematic view of the busbar assembly of the first embodiment of the utility model.

[0023] Figure 2B It is structural schematic view of the busbar assembly of the first embodiment of the utility model in another perspective.

[0024] Figure 3 It is Figure 2A Structural exploded view of the busbar assembly shown in the figure.

[0025] Figure 4 It isFigure 3 A structure diagram of the first phase busbar, the second phase busbar and the third phase busbar is shown.

[0026] Figure 5 A structure diagram of the neutral busbar is shown. Figure 3 A structure diagram of the neutral busbar is shown.

[0027] Figure 6A A structure diagram of the busbar assembly of the second embodiment of the utility model is shown.

[0028] Figure 6B A structure diagram of the busbar assembly of the second embodiment of the utility model is shown.

[0029] Figure 7 A structure diagram of the busbar assembly of the second embodiment of the utility model is shown.

[0030] Figure 8 A structure diagram of the busbar assembly of the second embodiment of the utility model is shown.

[0031] Figure 9 A structure diagram of the busbar assembly of the second embodiment of the utility model is shown.

[0032] The reference signs are as follows:

[0033] 1, 1a: busbar assembly

[0034] 10: first phase busbar

[0035] 11: first body

[0036] 11a: first plate surface

[0037] 11b: first side edge

[0038] 11c: second side edge

[0039] 12: first wiring portion

[0040] 13: first contact portion

[0041] 131: first contact portion terminal

[0042] 20: second phase busbar

[0043] 21: second body

[0044] 21a: second plate surface

[0045] 21b: first side edge

[0046] 21c: second side edge

[0047] 22: second wiring portion

[0048] 23: second contact portion

[0049] 231: second contact portion terminal

[0050] 30: third phase busbar

[0051] 31: third body

[0052] 31a: middle section

[0053] 31b: first extension portion

[0054] 31c: second extension portion

[0055] 31d: first bent section

[0056] 31e: second bent section

[0057] 311: first side edge

[0058] 312: second side edge

[0059] 32: fourth contact portion

[0060] 33: third contact portion

[0061] 331: third contact portion terminal

[0062] 40: neutral busbar

[0063] 41: fourth body

[0064] 41a: third bent section

[0065] 411: first side edge

[0066] 412: second side edge

[0067] 42: fourth contact portion

[0068] 421: fourth contact portion terminal

[0069] 50: base

[0070] 50a: upper surface

[0071] 50b: lower surface

[0072] 51: first side edge

[0073] 52: second side edge

[0074] 53: first insulating layer body

[0075] 53a: upper surface

[0076] 531: first mounting groove

[0077] 532: first fastener

[0078] 54: second insulating layer

[0079] 54a: upper surface

[0080] 54b: lower surface

[0081] 541: second mounting groove

[0082] 542: accommodating groove

[0083] 543: second fastener

[0084] 9: motor stator

[0085] 91: stator core

[0086] 911: hollow portion

[0087] 92: flat wire winding

[0088] 921: first phase winding

[0089] 922: second phase winding

[0090] 923: third phase winding

[0091] 924: neutral wire winding

[0092] 93: wire slot

[0093] 94: end portion

[0094] b: protrusion

[0095] c: recess

[0096] T: temperature sensor

[0097] D1: first direction

[0098] X, Y, Z: axes DETAILED DESCRIPTION

[0099] Some typical embodiments embodying features and advantages of the present application will be described in detail in the following description. It should be understood that the present application can have various changes in different ways, which do not deviate from the scope of the present application, and the description and drawings in the essence are used for explanation, not for limiting the present application. For example, if the following content of the present application describes that a first feature is arranged on or above a second feature, it means that it includes the embodiment in which the first feature and the second feature are directly contacted, and also includes the embodiment in which additional features can be arranged between the first feature and the second feature, so that the first feature and the second feature can not be directly contacted. In addition to the orientation shown in the drawings, the spatially related terms are used to cover different orientations of the device in use or operation. The device can also be positioned (for example, rotated by 90 degrees or located in other positions), and the description of the spatially related terms used is interpreted accordingly. In addition, when a component is referred to as "connected to" or "coupled to" another component, it can be directly connected or coupled to another component, or there can be intervening components. In addition, it can be understood that although the words "first", "second" and the like can be used in the claims to describe different components, these components should not be limited by these words, and the corresponding description of these components in the embodiments is represented by different component symbols. These words are used to distinguish different components. For example: the first component can be referred to as the second component, and similarly, the second component can be referred to as the first component, without deviating from the scope of the embodiments.

[0100] Please refer to Figure 1A , Figure 1B , Figure 2A , Figure 2B and Figure 3 The utility model discloses a busbar assembly 1, suitable for motor stator 9, wherein the motor stator 9 includes stator core 91 and a plurality of flat wire windings 92, a plurality of flat wire windings 92 are wound on the stator core 91, and the plurality of flat wire windings 92 include first phase winding 921, second phase winding 922, third phase winding 923 and at least one neutral line winding 924.

[0101] The busbar assembly 1 is disposed on the end portion 94 of the motor stator 9, and includes a first phase busbar 10, a second phase busbar 20, a third phase busbar 30, at least one neutral busbar 40, and a base 50. The first phase busbar 10 includes a first body 11, a first wiring portion 12, and at least one first contact portion 13, wherein the first wiring portion 12 and the at least one first contact portion 13 extend outwardly from at least one side of the first body 11, and the first contact portion 13 is configured to be electrically connected to the first phase winding 921. The second phase busbar 20 includes a second body 21, a second wiring portion 22, and at least one second contact portion 23, wherein the second wiring portion 22 and the at least one second contact portion 23 extend outwardly from at least one side of the second body 21, and the second contact portion 23 is configured to be electrically connected to the second phase winding 922. The third phase busbar 30 includes a third body 31, a third wiring portion 32, and at least one third contact portion 33, wherein the third wiring portion 32 and the at least one third contact portion 33 extend outwardly from one side of the third body 31, and the third contact portion 33 is configured to be electrically connected to the third phase winding 923. The neutral busbar 40 includes a fourth body 41 and at least one fourth contact portion 42, wherein the at least one fourth contact portion 42 extends outwardly from one side of the fourth body 41, and the fourth contact portion 42 is configured to be electrically connected to the neutral winding 924. In one embodiment, the base 50 includes an upper surface 50a and a lower surface 50b, and the busbar assembly 1 and the motor stator 9 are positioned and assembled by a process jig, so that the lower surface 50b of the base 50 is in contact with the end portion 94 of the motor stator 9, and then a welding process is performed.

[0102] The base 50 includes a first side 51, a second side 52, a first insulating layer 53, and a second insulating layer 54, wherein the second insulating layer 54 is disposed on the first insulating layer 53 and connected to each other. In this embodiment, the first body 11 of the first phase busbar 10 and the second body 21 of the second phase busbar 20 are each at least partially disposed on the first insulating layer 53 and separated from each other. The first wiring portion 12 is exposed from the first side 51 of the base 50 and extends in the first direction D1, and the second wiring portion 22 is exposed from the second side 52 of the base 50 and extends in the first direction D1. At least one first contact portion 13 and at least one second contact portion 23 are exposed from at least one of the first side 51 and the second side 52 of the base 50 and extend in the first direction D1. In one embodiment, the first direction D1 is perpendicular to the upper surface 50a of the base 50. By interposing a portion of the material of the first insulating layer 53 between the first body 11 and the second body 21, the required electrical safety distance between the two is maintained, thereby improving electrical isolation. In this embodiment, the third phase bus 30 and the at least one neutral bus 40 are fixed to the upper surface 50a of the base 50 and are separated from each other. The third wiring portion 32 is located on the upper surface of the second insulating layer 54 and extends in the first direction D1. At least one third contact portion 33 and at least one fourth contact portion 42 are located on the upper surface of the second insulating layer 54 and extend in the first direction D1. By interposing a portion of the material of the second insulating layer 54 between the third phase bus 30 and the at least one neutral bus 40, the required electrical safety distance between them is maintained, thereby improving electrical isolation. In addition, through the double-layer setting of the first insulating layer 53 and the second insulating layer 54, the first phase bus 10 and the second phase bus 20 located in the first insulating layer 53 are isolated from each other from the third phase bus 30 and at least one neutral line bus 40 located in the second insulating layer 54 to improve electrical safety, and the size of the components can be reduced through spatial arrangement.

[0103] See also Figure 3 and Figure 4In one embodiment, the first body 11 is a plate having a first plate surface 11a, wherein the first plate surface 11a is flush with the upper surface 53a of the first insulating layer 53. The first connection portion 12 of the first phase busbar 10 extends vertically outward from the first side 11b of the first body 11. The first phase busbar 10 includes a plurality of first contact portions 13, some of which extend vertically outward from the first side 11b of the first body 11, and the remaining first contact portions 13 extend vertically outward from the second side 11c of the first body 11. In one embodiment, the second body 21 is a plate having a second plate surface 21a, wherein the second plate surface 21a is flush with the upper surface 53a of the first insulating layer 53. The second connection portion 22 of the second phase busbar 20 extends vertically outward from the second side 21c of the second body 21. The second phase busbar 20 includes a plurality of second contact portions 23. Some of the second contact portions 23 extend vertically outward from the first side 21b of the second body 21, while the remaining second contact portions 23 extend vertically outward from the second side 21c of the second body 21. In one embodiment, the first body 11 of the first phase busbar 10 and the second body 21 of the second phase busbar 20 are each at least partially embedded in the first insulating layer 53. In this embodiment, the upper surface 50a of the base 50 is located in a plane defined by the second direction and the third direction, wherein the first direction, the second direction, and the third direction are perpendicular to each other, with the first direction being the z-axis, the second direction being the x-axis, and the third direction being the y-axis. The upper surface 50a of the base 50 is located in the XY plane.

[0104] In one embodiment, the third body 31 is an elongated plate and includes a middle section 31a, a first extension 31b, and a second extension 31c. The first extension 31b and the second extension 31c are connected to opposite sides of the middle section 31a. The first extension 31b is perpendicularly connected to the middle section 31a and has a first bend 31d. The second extension 31c is connected to the middle section 31a at an angle greater than 90 degrees and has a second bend 31e. The third connection portion 32 of the third phase busbar 30 is connected to the first side 311 of the third body 31. The third phase busbar 30 includes a plurality of third contact portions 33, some of which are connected to a side of the first extension 31b, while the remaining third contact portions 33 are connected to a side of the second extension 31c. The third body 31 contacts or is disposed on the upper surface 54 a of the second insulating layer 54 through the second side 312 , and the third wiring portion 32 and the plurality of third contact portions 33 are perpendicular to the upper surface 54 a of the second insulating layer 54 .

[0105] See also Figure 3 and Figure 5In one embodiment, the busbar assembly 1 includes two neutral busbars 40, but is not limited thereto. The fourth body 41 of each neutral busbar 40 is a long strip member and includes a third bent section 41a. The neutral busbar 40 includes a plurality of fourth contact portions 42 connected to a first side edge 411 of the fourth body 41, respectively. The fourth body 41 contacts or is disposed on the upper surface 54a of the second insulating layer 54 by a second side edge 412, and the plurality of fourth contact portions 42 are perpendicular to the upper surface 54a of the second insulating layer 54.

[0106] Please refer to Figure 2A , Figure 2B and Figure 3 again. In the present embodiment, the base 50 is a one-piece structure integrally formed by overmolding, such that the first insulating layer 53 and the second insulating layer 54 are connected and formed as a one-piece structure. In this way, the number of components of the busbar assembly 1 is reduced, and the assembly process is simplified, which can greatly improve the assembly efficiency and reduce the human error during the assembly operation. In the present embodiment, the base 50 at least partially covers the first phase busbar 10 and the second phase busbar 20. Specifically, the first body 11 and the second body 21 are covered and embedded in the base 50, and the first wiring portion 12, the second wiring portion 22, the first contact portion 13, and the second contact portion 23 are exposed from at least one of the first side edge 51 and the second side edge 52 of the base 50 and extend in the first direction D1. In one embodiment, the second side edge 312 of the third body 31 of the third phase busbar 30 and the second side edge 412 of the fourth body 41 of the neutral busbar 40 are partially embedded in the base 50, such that the third phase busbar 30 and the two neutral busbars 40 are fixed to the upper surface 50a of the base 50 and are separated from each other. The first phase busbar 10, the second phase busbar 20, the third phase busbar 30, and the two neutral busbars 40 can be fixed by the base 50 and arranged to be isolated from each other. In addition, the first phase busbar 10 and the second phase busbar 20 are arranged on the first insulating layer 53, and the third phase busbar 30 and the two neutral busbars 40 are arranged on the second insulating layer 54, such that the third phase busbar 30 and the two neutral busbars 40 are arranged vertically above the first phase busbar 10 and the second phase busbar 20, thereby reducing the size of the busbar assembly through spatial arrangement. In addition, the structural profile design and spatial arrangement of each phase busbar and neutral busbar can achieve the effects of reducing the size of the busbar assembly, simplifying and facilitating the assembly operation, and improving electrical safety. Furthermore, each busbar is preferably made of copper, which has a simple profile and reduces the generation of excess material during the forming process, thereby reducing material costs. In addition, the wiring portions and contact portions of each busbar are arranged in the same direction as the first direction D1, i.e., in the direction away from the upper surface 50a of the base 50, thereby facilitating subsequent wire welding operations and reducing production costs.

[0107] In one embodiment, the base 50 of the busbar assembly 1 further comprises a sensor accommodating groove 542 disposed on the upper surface 54a of the second insulating layer 54 for accommodating the temperature sensor T to facilitate temperature detection of the motor stator 9.

[0108] In one embodiment, the stator core 91 comprises a hollow portion 911 and a plurality of wire slots 93, and the plurality of flat wire windings 92 are disposed in the corresponding wire slots 93. In this embodiment, the first-phase busbar 10 is a U-phase busbar, the second-phase busbar 20 is a W-phase busbar, the third-phase busbar 30 is a V-phase busbar, and the neutral busbar is a Y-phase busbar, but the present application is not limited thereto.

[0109] Referring to Figure 6A and Figure 6B , which are structural schematic diagrams of the busbar assembly of the second embodiment of the present application. In this embodiment, the structures and functions of the elements of the busbar assembly 1a are the same as those of the busbar assembly 1 of the first embodiment, wherein the same element numbers represent the same elements and functions, and will not be described here. Unlike the busbar assembly 1 of the first embodiment, the first insulating layer 53 and the second insulating layer 54 of the busbar assembly 1a of the present embodiment are separate components, and can be connected by a mechanical assembly method.

[0110] Referring to Figure 7 , Figure 8 and Figure 9 . The first insulating layer 53 comprises two first mounting grooves 531 disposed on the upper surface 53a of the first insulating layer 53 for positioning and assembling the first body 11 of the first-phase busbar 10 and the second body 21 of the second-phase busbar 20. In this embodiment, the first body 11 and the second body 21 are preferably designed in an arc shape, and the first wiring portion 12 is disposed on the first side edge 51 of the base 50, and the second wiring portion 22 is disposed on the second side edge 52 of the base 50. Since the outer contour of the first body 11 and the second body 21 matches the contour of the corresponding first mounting groove 531, they can be tightly fitted. In addition, the first insulating layer 53 comprises four protrusions b, two of which are connected with one of the first mounting grooves 531, and the other two are connected with the other first mounting groove 531. The first-phase busbar 10 and the second-phase busbar 20 each comprise two recesses c, each recess c of the first-phase busbar 10 and each recess c of the second-phase busbar 20 are respectively assembled and engaged with the protrusion b of the corresponding first mounting groove 531, so that the first-phase busbar 10 and the second-phase busbar 20 can be stably disposed in the base 50.

[0111] In the present embodiment, the second insulating layer 54 includes a plurality of second mounting grooves 541 disposed on the upper surface 54a of the second insulating layer 54 for positioning and assembling the third phase busbar 30 and the two neutral busbars 40, so that the third phase busbar 30 and the neutral busbars 40 are fixedly arranged on the upper surface 54a of the second insulating layer 54. In addition, the second insulating layer 54 includes a lower surface 54b opposite to the upper surface 54a of the second insulating layer 54, and the lower surface 54b is in close contact with the first plate surface 11a of the first body 11 of the first phase busbar 10 and the second plate surface 21a of the second body 21 of the second phase busbar 20. By abutting the first phase busbar 10 and the second phase busbar 20 against the lower surface 54b of the second insulating layer 54, and by the thickness of the second insulating layer 54, the first phase busbar 10 and the second phase busbar 20 arranged on the first insulating layer 53 are separated from the third phase busbar 30 and the two neutral busbars 40 arranged on the second insulating layer 54, thereby improving electrical safety.

[0112] In the present embodiment, the third wiring portion 32 of the third phase busbar 30 is arranged between the first side edge 51 and the second side edge 52 of the base 50. Since the first wiring portion 12 of the first phase busbar 10 is exposed from the first side edge 51 of the base 50, the second wiring portion 22 of the second phase busbar 20 is exposed from the second side edge 52 of the base 50, and the first wiring portion 12, the second wiring portion 22 and the third wiring portion 32 protrude from the upper surface 50a of the base 50 and extend away from the upper surface 50a (i.e. extend in the first direction D1), by arranging the first wiring portion 12, the second wiring portion 22 and the third wiring portion 32 at different positions of the busbar assembly 1, subsequent welding operations with external wires can be facilitated.

[0113] In the present embodiment, the first contact portion 13 includes a first contact portion terminal 131, the second contact portion 23 includes a second contact portion terminal 231, the third contact portion 33 includes a third contact portion terminal 331, and the fourth contact portion 42 includes a fourth contact portion terminal 421, wherein the first contact portion terminal 131 and the second contact portion terminal 231 are lower than the third contact portion terminal 331 and the fourth contact portion terminal 421 in the first direction D1. By staggered arrangement of the contact portion terminals in space, subsequent contact and connection operations with flat wire windings can be facilitated.

[0114] Figure 6A 、 Figure 6B 、 Figure 7 、 Figure 8 and Figure 9In this embodiment, the first insulating layer 53 includes at least one first fastener 532. Some of the first fasteners 532 are disposed adjacent to the first side edge 51 of the base 50, and the rest of the first fasteners 532 are disposed adjacent to the second side edge 52 of the base 50. After the first busbar 10 and the second busbar 20 are disposed in the first mounting groove 531 of the first insulating layer 53, the first fasteners 532 are used to fasten the corresponding side edges of the second insulating layer 54, thereby connecting and combining the first insulating layer 53 and the second insulating layer 54. In this embodiment, the first insulating layer 53 preferably has four first fasteners 532, but is not limited thereto.

[0115] In this embodiment, the second insulating layer 54 includes at least one second fastener 543. The second insulating layer 54 preferably has six second fasteners 543, but is not limited thereto. In one embodiment, some of the second fasteners 543 are disposed adjacent to the first side edge 51 of the base 50, and the rest of the second fasteners 543 are disposed adjacent to the second side edge 52 of the base 50. When the third busbar 30 and the two neutral busbars 40 are disposed on the upper surface 54a of the second insulating layer 54, the third busbar 30 and the two neutral busbars 40 are first disposed in the second mounting groove 541, and then fastened to the side edges of the third busbar 30 and the two neutral busbars 40 by the corresponding second fasteners 543, so that the third busbar 30 and the two neutral busbars 40 are fixedly disposed on the upper surface 54a of the second insulating layer 54. In this embodiment, the third busbar 30 and the two neutral busbars 40 are fastened by two corresponding second fasteners 543. In this embodiment, since the first insulating layer 53 and the second insulating layer 54 of the base 50 are detachably connected, it is convenient to maintain or replace the busbar assembly 1a. It should be emphasized that the number of the first fasteners 532 and the second fasteners 543 is not limited to this embodiment, and can be adjusted according to application requirements.

[0116] In summary, the utility model provides a busbar assembly suitable for motor stator, through the structure contour design and the arrangement and disposition in space of each busbar and base, can reach the effect that reduces busbar assembly size, reduces material cost, simplifies and facilitates assembly operation and promotes electrical safety. In addition, through the one-piece structure design of the first insulating layer body and the second insulating layer body of base or the combined structure design of the first insulating layer body and the second insulating layer body that can be mutually clamped, the first phase busbar and the second phase busbar can be arranged on the first insulating layer body, the third phase busbar and at least one neutral busbar are arranged on the second insulating layer body, and the above-mentioned elements are separated from each other, thereby the electrical safety of busbar assembly can be improved, the busbar assembly size can be reduced, and the assembly operation can be simplified and facilitated. In addition, the base of busbar assembly includes sensor setting seat, a temperature sensor can be arranged, which is helpful for the installation of temperature sensor and facilitates the temperature detection of motor stator by temperature sensor.

[0117] The utility model can be modified by the person skilled in the art, but all do not deviate from the protection of the appended claims.

Claims

1. A busbar assembly for a motor stator, wherein the motor stator comprises a stator core and a plurality of flat wire windings, the plurality of flat wire windings being wound around the stator core, and the plurality of flat wire windings comprising a first phase winding, a second phase winding, a third phase winding, and at least one neutral winding, wherein: The busbar assembly is disposed at one end of the motor stator and includes: a first-phase busbar comprising a first body, a first connection portion, and at least one first contact portion, wherein the first connection portion and the at least one first contact portion extend outwardly from at least one side of the first body, and the first contact portion is configured to be electrically connected to the first-phase winding; a second-phase busbar comprising a second body, a second connection portion, and at least one second contact portion, wherein the second connection portion and the at least one second contact portion extend outwardly from at least one side of the second body, and the second contact portion is configured to be electrically connected to the second-phase winding; a third-phase busbar comprising a third body, a third connection portion, and at least one third contact portion, wherein the third connection portion and the at least one third contact portion extend outwardly from a side edge of the third body, and the third contact portion is configured to be electrically connected to the third-phase winding; At least one neutral busbar, each of the neutral busbars comprising a fourth body and at least one fourth contact portion, wherein the at least one fourth contact portion extends outward from a side of the fourth body and is configured to be conductively connected to the at least one neutral winding; and A base includes a first side, a second side, a first insulating layer, and a second insulating layer. wherein the second insulating layer is disposed on the first insulating layer and connected to each other, wherein the first body of the first phase busbar and the second body of the second phase busbar are respectively at least partially disposed on the first insulating layer and separated from each other, the first wiring portion is exposed from the first side of the base and extends in a first direction, the second wiring portion is exposed from the second side of the base and extends in the first direction, the at least one first contact portion and the at least one second contact portion are respectively exposed from at least one of the first side and the second side of the base and extend in the first direction, The third phase bus and the at least one neutral line bus are arranged on an upper surface of the second insulating layer and are separated from each other, the third wiring portion is located on the upper surface of the second insulating layer and extends in the first direction, and the at least one third contact portion and the at least one fourth contact portion are located on the upper surface of the second insulating layer and extend in the first direction.

2. The busbar assembly according to claim 1, wherein: The base is a one-piece structure formed integrally, and the base is formed by coating injection molding so that the base at least partially covers the first phase bus and the second phase bus, and the third phase bus and the at least one neutral line bus are respectively at least partially embedded in the base, so that the third phase bus and the at least one neutral line bus are fixed to the base.

3. The busbar assembly according to claim 1, wherein: The first insulating layer body includes a plurality of first mounting grooves, which are arranged on an upper surface of the first insulating layer body for positioning and assembling the first body of the first-phase busbar and the second body of the second-phase busbar.

4. The busbar assembly according to claim 3, wherein: The first insulating layer includes at least one convex portion, each of which is connected to the corresponding first mounting groove, wherein the first phase busbar and the second phase busbar each include at least one concave portion, and the at least one concave portion is assembled and engaged with the at least one convex portion.

5. The busbar assembly according to claim 1, wherein: The second insulating layer body includes a plurality of second installation grooves, which are arranged on the upper surface of the second insulating layer body for positioning and assembling the third phase bus bar and the at least one neutral line bus bar.

6. The busbar assembly according to claim 1, wherein: The second insulating layer body includes a sensor accommodating seat, which is arranged on the upper surface of the second insulating layer body and is structured to accommodate a temperature sensor.

7. The busbar assembly according to claim 1, wherein: The second insulating layer includes a lower surface, and the lower surface is closely attached to the first body of the first-phase busbar and the second body of the second-phase busbar.

8. The busbar assembly according to claim 1, wherein: The third connection portion of the third phase bus is arranged between the first side and the second side of the base, and the upper surface of the base is located in a plane formed by a second direction and a third direction, wherein the first direction, the second direction and the third direction are perpendicular to each other.

9. The busbar assembly according to claim 1, wherein: The first contact portion includes a first contact terminal, the second contact portion includes a second contact terminal, the third contact portion includes a third contact terminal, and the fourth contact portion includes a fourth contact terminal. The first contact terminal and the second contact terminal are lower than the third contact terminal and the fourth contact terminal in the first direction.

10. The busbar assembly according to claim 1, wherein: The first insulating layer body includes at least one first fastener, which is adjacent to at least one of the first side and the second side of the base. The first insulating layer body is fastened to a corresponding side of the second insulating layer body through the at least one first fastener of the first insulating layer body, so that the first insulating layer body and the second insulating layer body are connected and combined.

11. The busbar assembly according to claim 1, wherein: The second insulating layer body includes at least one second fastener, which is adjacent to at least one of the first side and the second side of the base. The at least one second fastener of the second insulating layer body is fastened to the side of the third phase bus and the at least one neutral line bus, so that the third phase bus and the at least one neutral line bus are fixed to the upper surface of the second insulating layer body.

12. The busbar assembly according to claim 1, wherein: The first-phase busbar is a U-phase busbar, the second-phase busbar is a W-phase busbar, the third-phase busbar is a V-phase busbar, and the neutral line busbar is a Y-connected busbar.

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