Flat wire stator slot bottom injection molding iron core
By adopting an integrated injection-molded insulating medium and optimizing the structural design in the stator core, the insulation and stability problems of traditional stator cores have been solved, resulting in higher insulation performance and improved motor efficiency.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-30
- Publication Date
- 2026-04-07
AI Technical Summary
Traditional stator cores have shortcomings in terms of insulation performance and structural stability. They are prone to leakage and short circuit problems, especially in high-power, high-speed motors. In addition, the injection-molded ring is inconvenient to install and its excessive height affects the quality of the motor.
The stator body is formed by stacking silicon steel sheets and then injection molding to form an integrated insulating medium, including a ring-shaped body and a toothed structure. The thickness and width ratio of the insulating medium are optimized, and combined with the toothed slot design, an integrated insulating structure is formed to replace traditional insulating paper.
It improves insulation performance and structural stability, reduces wire length and material usage, enhances motor operating safety and efficiency, and simplifies the production process.
Smart Images
Figure CN224097473U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the field of motor stator manufacturing technology, and relates to a stator, specifically a flat wire stator injection molded iron core with flat wires. Background Technology
[0002] The stator core is a common motor structure, playing a crucial role in motor operation. Traditional stator cores have certain shortcomings in insulation performance and structural stability. Ordinary insulation methods, often using insulating paper, are insufficient to meet the insulation reliability requirements of high-power, high-speed motors, easily leading to leakage, short circuits, and other problems that affect the motor's normal operation and lifespan. Furthermore, the structural stability of the stator core faces challenges in complex operating environments, potentially causing a decline in motor performance. Therefore, developing a flat-wire injection-molded stator core with good insulation performance and a stable structure is of significant practical importance.
[0003] To replace the use of insulating paper, a Chinese utility model patent filed on May 14, 2024, with application number 2024210389551, discloses a motor stator structure. This stator structure includes a stator core, an insulating frame, stator windings, and a winding lead assembly. The stator windings include a first winding, a second winding, and a third winding formed by winding a single enameled wire. The first, second, and third windings are connected in a delta circuit. The winding lead assembly includes a U-phase lead plate, a V-phase lead plate, a W-phase lead plate, and an injection-molded ring. The injection-molded ring covers the U-phase, V-phase, and W-phase lead plates, which are spaced apart from each other. Each lead plate is connected to a terminal and a insert extending from the injection-molded ring. The injection-molded ring is connected to the insulating frame via a connecting part. The stator structure of this motor uses an insulating frame and an injection-molded ring to prevent leakage and short circuits, thus improving the performance of the stator core. However, the above technical solution relies on the insulating frame and the injection-molded ring to provide insulation, with the wires wrapped inside the injection-molded ring, which is mounted on the insulating frame. This installation method is inconvenient, and the excessive height of the injection-molded ring affects the quality of the motor stator. Utility Model Content
[0004] The purpose of this utility model is to overcome the technical problems of inconvenient installation of the stator core injection ring and excessive height of the injection ring in the prior art, and to provide a flat wire stator slot bottom injection molded iron core that can reduce the height of the injection ring or the height of the insulating paper, is easy to manufacture, can provide better insulation effect, and can save wire materials.
[0005] To solve the above-mentioned technical problems, this utility model provides a flat wire stator slot bottom injection molded iron core, including a stator body made of stacked silicon steel sheets. The stator body includes an annular body one, which forms a yoke. An inwardly protruding rack one is provided in the inner circle of the yoke one. A tooth groove is provided between adjacent racks. An insulating medium one formed by injection molding is provided around the inner wall of the tooth groove. An insulating medium two formed by injection molding is provided on the upper surface of the stator body. The insulating medium two includes an annular body two and a rack two set in the inner circle of the annular body two. An insulating medium three formed by injection molding is provided on the lower surface of the stator body. The insulating medium three includes an annular body three and a rack three set in the inner circle of the annular body three. The insulating medium one, the insulating medium two, and the insulating medium three are an integral structure formed by injection molding. The thickness of the insulating medium one is 0.15-0.22mm.
[0006] As a further improvement of this utility model, in the above-mentioned flat wire stator slot bottom injection molded iron core, the thickness of the second and third insulating media is set to 1-1.5mm. Such a thickness setting ensures good insulation effect without increasing excessive weight and cost.
[0007] As a further improvement of this utility model, in the above-mentioned flat wire stator slot bottom injection molded iron core, the width of the second and third annular bodies is smaller than the width of the first annular body.
[0008] As a further improvement of this utility model, in the above-mentioned flat wire stator slot bottom injection molded iron core, the width ratio of the second and third annular bodies to the width of the first annular body is 1:3-4. This width ratio design helps to optimize the overall structure of the iron core and improve its stability.
[0009] As a further improvement of this utility model, in the above-mentioned flat wire stator slot bottom injection molded iron core, the width of rack two and rack three is equal to or slightly smaller than the width of the rack. This design makes the structural strength of the iron core more balanced in various parts, which is conducive to the uniform distribution of current and the stable generation of magnetic field.
[0010] As a further improvement of this utility model, the above-mentioned flat wire stator slot bottom injection molded iron core has an annular body four for connecting each rack in the inner ring of rack two, and an annular body five for connecting each rack in the inner ring of rack three. The arrangement of annular body four and annular body five further enhances the integrity and stability of the iron core structure.
[0011] As a further improvement of this utility model, the above-mentioned flat wire stator slot bottom injection molded iron core has a toothed groove slit in the inner ring of the toothed groove of the stator body, and a protruding strip is provided near the inner ring of the insulating medium, and the protruding strip is provided in the toothed groove slit.
[0012] Compared with the prior art, the beneficial effects of this utility model are as follows: 1. The connection between silicon steel sheets is fastened by injection molding, avoiding the increase in iron loss caused by local conductive bands in silicon steel due to snap-fitting and welding; 2. The two ends of the iron core are made of injection-molded insulator medium two and insulator medium three, which effectively shortens the height of the two ends, reduces the creepage distance of the wires, reduces the length of the wires, and saves materials; 3. Insulator medium one, insulator medium two, and insulator medium three are integrally injection molded, which can improve production efficiency and solve the problem of cross-movement of insulation paper caused by insertion and winding; 4. The bottom of the iron core slot is made of injection-molded plastic instead of insulation paper, which has better anti-slip properties and thermal conductivity, effectively improving motor efficiency by about 10% and improving product quality. Attached Figure Description
[0013] Figure 1 This is a front view of a flat wire stator slot bottom injection molded iron core according to this utility model.
[0014] Figure 2 This is a perspective view of a flat wire stator slot bottom injection molded iron core according to this utility model.
[0015] Figure 3 This is the front view of the main body of this utility model.
[0016] Figure 4 yes Figure 3 Enlarged view of point A in the middle.
[0017] Figure 5 This is a front view of insulating medium one, insulating medium two, and insulating medium three of this utility model.
[0018] Figure 6 yes Figure 5 Cross-sectional view along the BB direction.
[0019] Figure 7 yes Figure 5 Enlarged view of point C.
[0020] Figure 8 This is a rear view of insulating medium one, insulating medium two, and insulating medium three of this utility model.
[0021] Figure 9 This is a perspective view of insulating medium one, insulating medium two, and insulating medium three of this utility model.
[0022] Explanation of the reference numerals: 1. Ring body one; 2. Yoke; 3. Rack one; 4. Gutter; 5. Insulator medium one; 6. Insulator medium two; 7. Ring body two; 8. Rack two; 9. Insulator medium three; 10. Ring body three; 11. Rack three; 12. Ring body four; 13. Ring body five; 14. Raised bar; 15. Gutter. Detailed Implementation
[0023] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely for explaining the present utility model and are not intended to limit the present utility model.
[0024] Conversely, this utility model covers any substitutions, modifications, equivalent methods, and solutions made within the spirit and scope of this utility model as defined by the claims. Furthermore, to provide the public with a better understanding of this utility model, certain specific details are described in detail below; however, those skilled in the art can fully understand this utility model even without these detailed descriptions.
[0025] like Figure 1 , Figure 2 , Figure 3 , Figure 6 and Figure 9 The diagram illustrates a flat wire stator slot bottom injection-molded iron core, comprising a stator body made of stacked silicon steel sheets. The silicon steel sheets are connected by injection molding to avoid increased iron loss due to localized conductive bands caused by riveting and welding. The stator body includes an annular body 1, which forms a yoke 2. An inwardly protruding rack 3 is provided within the inner ring of the yoke 2 of the annular body 1. Gutters 4 are provided between adjacent racks 3. An insulator medium 5, formed by injection molding, is provided around the inner wall of the grooves 4. An insulator medium 2 6, also formed by injection molding, is provided on the upper surface of the stator body. The insulator medium 2 6 includes an annular body 2 7 and racks 2 8 arranged within the inner ring of the annular body 2 7. Figure 5 , Figure 6 and Figure 7 As shown, an insulator dielectric 3 9, formed by injection molding, is provided on the lower surface of the stator body. The insulator dielectric 3 9 includes an annular body 3 10 and a rack 3 11 disposed in the inner ring of the annular body 3 10. The use of injection-molded insulator dielectric 2 and insulator dielectric 3 at both ends of the iron core effectively shortens the height at both ends, reduces the creepage distance of the conductors, reduces the length of the conductors, and saves materials.
[0026] like Figure 1 , Figure 5 , Figure 8 , Figure 9 As shown, the widths of annular body 2 (7) and annular body 3 (10) are smaller than the width of annular body 1 (1). The ratio of the widths of annular body 2 (7) and annular body 3 (10) to the width of annular body 1 (1) is 1:3. This width ratio design helps to optimize the overall structure of the iron core and improve its stability.
[0027] like Figure 9As shown, insulator medium 1 (5), insulator medium 2 (6), and insulator medium 3 (9) are an integral structure formed by injection molding. The thickness of insulator medium 1 (5) is 0.18 mm. This can improve the insulation performance and facilitate the installation of subsequent wires, thereby improving production efficiency and solving the problem of cross-movement of the insulation paper caused by wire insertion and winding.
[0028] like Figure 6 , Figure 9 As shown, the thickness of insulator medium 6 is set to 1.25mm, and the thickness of insulator medium 9 is set to 1.25mm. This thickness setting ensures good insulation effect. By reducing the height of the insulation layer at both ends of the iron core, the length of the conductor can be reduced, thus saving materials.
[0029] like Figure 1 , Figure 2 , Figure 3 and Figure 9 As shown, the widths of rack 2 (8) and rack 3 (11) are equal to the width of rack 1 (3). This design makes the structural strength of the iron core more balanced in various parts, which is conducive to the uniform distribution of current and the stable generation of magnetic field.
[0030] like Figure 5 , Figure 8 and 9 As shown, an annular body 4 12 for connecting each rack is provided in the inner ring of rack 2 8, and an annular body 5 13 for connecting each rack is provided in the inner ring of rack 3 11. The arrangement of annular body 4 12 and annular body 5 13 further enhances the integrity and stability of the core structure.
[0031] like Figure 4 , Figure 7 As shown, the inner ring of the tooth groove 4 of the stator body is provided with a tooth groove 15, and the insulating medium 5 is provided with a protrusion 14 near the inner ring. The protrusion 14 is provided in the tooth groove 15.
[0032] By injection molding insulating media 1 (5), insulating media 2 (6), and insulating media 3 (9) into an integral structure on the inner wall of the slot 4 and the upper and lower surfaces of the stator body, production efficiency and product quality can be improved. This significantly enhances the insulation performance of the core, effectively preventing leakage and short circuits, and improving the safety and reliability of motor operation. Through reasonable thickness settings and structural dimension ratios, the core structure is optimized while ensuring insulation performance. The bottom of the core slot uses injection-molded plastic instead of insulating paper, which has better anti-slip properties and thermal conductivity, effectively improving motor efficiency by about 10% and enhancing product quality.
[0033] The embodiments of the present utility model have been described in detail above with reference to the accompanying drawings. However, the present utility model is not limited to the above embodiments. For those skilled in the art, several modifications and improvements can be made without departing from the present utility model, and these should also be considered to fall within the protection scope of the present utility model.
Claims
1. A flat wire stator slot bottom injection molded iron core, comprising a stator body made of stacked silicon steel sheets, wherein the stator body comprises an annular body (1), the annular body (1) forming a yoke (2), a protruding toothed rack (3) is provided in the inner ring of the yoke (2) of the annular body (1), and toothed grooves (4) are provided between adjacent toothed racks (3), characterized in that, An insulating medium one (5) formed by injection molding is provided around the inner wall of the tooth groove (4). An insulating medium two (6) formed by injection molding is provided on the upper surface of the stator body. The insulating medium two (6) includes an annular body two (7) and a toothed rack two (8) arranged in the inner ring of the annular body two (7). An insulating medium three (9) formed by injection molding is provided on the lower surface of the stator body. The insulating medium three (9) includes an annular body three (10) and a toothed rack three (11) arranged in the inner ring of the annular body three (10). The insulating medium one (5), the insulating medium two (6), and the insulating medium three (9) are an integral structure formed by injection molding. The thickness of the insulating medium one (5) is 0.15-0.22 mm.
2. The flat wire stator slot bottom injection molded iron core according to claim 1, characterized in that: The thickness of the second insulating medium (6) and the third insulating medium (9) is set to 1-1.5 mm.
3. The flat wire stator slot bottom injection molded iron core according to claim 1, characterized in that: The widths of ring two (7) and ring three (10) are smaller than the width of ring one (1).
4. A flat wire stator slot bottom injection molded iron core according to claim 3, characterized in that: The width of ring body two (7) and ring body three (10) is 1:3-4 to the width of ring body one (1).
5. A flat wire stator slot bottom injection molded iron core according to claim 1, characterized in that: The widths of rack two (8) and rack three (11) are equal to or slightly smaller than the width of rack one (3).
6. A flat wire stator slot bottom injection molded iron core according to claim 1, characterized in that: A ring-shaped body four (12) for connecting each rack is provided in the inner ring of rack two (8), and a ring-shaped body five (13) for connecting each rack is provided in the inner ring of rack three (11).
7. A flat wire stator slot bottom injection molded iron core according to claim 1, characterized in that: The inner ring of the tooth groove (4) of the stator body is provided with a tooth groove slot (15), and the insulating medium (5) is provided with a protrusion (14) near the inner ring. The protrusion (14) is provided in the tooth groove slot (15).