Monolithic efficient winding module

Abstract

The utility model belongs to the technical field of winding modules, and particularly relates to a single-piece type efficient winding module which comprises a stator single piece. A coil holder is sleeved on the stator single sheet, a winding position is arranged on the coil holder, a lead is wound on the winding position, and the lead comprises a copper foil layer and an insulating layer; the insulating layer is pressed on the copper foil layer; the copper foil layer is provided with at least one through eddy current inhibition groove, and the eddy current inhibition groove is used for preventing eddy current loss. The eddy current suppression groove is filled with insulating glue, and the filling of the insulating glue can thoroughly block a conductive path in the eddy current suppression groove. The single-layer insulating layer and the copper foil layer are arranged to replace an existing enameled wire for winding, the thickness is saved, meanwhile, the copper foil has the flat rectangular section, can be tightly attached to the groove wall of the winding position, almost has no gap filling, and is high in copper filling rate, so that the space utilization rate is increased, and the motor efficiency and the power density are high.

Description

Technical Field

[0001] This utility model belongs to the technical field of winding module, and in particular relates to a single-piece high-efficiency winding module. Background Technology

[0002] Traditional winding modules use copper wire (enameled wire) with a circular cross-section, commonly used in small and medium power motors, transformers, and inductors. With technological advancements, flat wire winding modules have emerged in the fields of new energy and robotics, using flat copper wire with a rectangular cross-section (such as hairpin windings). For example, CN215378585U discloses a stator core structure for traction machines, including a strip with multiple slots spaced apart along its length. A winding post is formed between adjacent slots. The strip is spirally stacked to form a core, which is a hollow cylinder. During the spiral stacking process, the winding posts overlap to form a winding module for winding coils, which improves the production efficiency of stator cores.

[0003] The aforementioned patent uses traditional enameled wire for winding. While flat wire winding modules have emerged with advancements in technology, resulting in improved copper fill ratios compared to traditional enameled wire winding, they still cannot meet the demands of motors in the new energy and robotics fields. Issues such as insufficient copper fill ratio, low space utilization, and consequently low motor efficiency and power density persist. Utility Model Content

[0004] The purpose of this invention is to provide a single-piece high-efficiency winding module, which aims to solve the problems in the background art of "insufficient copper filling rate of the winding module, low space utilization, resulting in low motor efficiency and low power density".

[0005] To achieve the above objectives, this utility model provides a single-piece high-efficiency winding module, including a stator single piece; a wire frame is sleeved on the stator single piece, the wire frame has winding positions, and a wire is wound on the winding positions, the wire including a copper foil layer and an insulating layer; the insulating layer is pressed onto the copper foil layer; the copper foil layer has at least one through-hole eddy current suppression groove, the eddy current suppression groove is used to prevent eddy current loss; the eddy current suppression...

[0006] Optionally, the width of the eddy current suppression groove is 0.02 to 0.3 mm.

[0007] Optionally, the copper foil layer is provided with lead-in terminals for electrical connection.

[0008] Optionally, the wire frame includes a first blocking part and a second blocking part; the first blocking part and the second blocking part are connected by a connecting part, and the winding position is formed between the first blocking part, the second blocking part and the connecting part, and the wire is wound around the connecting part.

[0009] Optionally, the winding position includes two symmetrically arranged clearance positions; after the two stator pieces are spliced ​​together, a gap is formed between the two adjacent clearance positions, and the width of the gap gradually narrows from the outside to the inside. When the conductor is wound around the wire frame, its winding thickness gradually decreases along the narrowing direction of the gap, so that the outer surface of the wound conductor matches the contour of the clearance position.

[0010] Optionally, the area of ​​the insulating layer is larger than the area of ​​the copper foil layer, so that the insulating layer can completely cover the copper foil layer.

[0011] Optionally, the insulating layer material is a polymer insulating film or a composite insulating film, wherein the polymer insulating film is one of polyimide, polyester, polyethylene naphthalate, and polytetrafluoroethylene.

[0012] Optionally, the stator single piece includes a connecting surface; the two ends of the connecting surface are respectively provided with a connecting groove and a connecting protrusion, and when two stator single pieces are spliced, the connecting protrusion of one stator single piece is inserted into the connecting groove of the other stator single piece.

[0013] Optionally, the wire frame is a split structure, comprising two symmetrically arranged parts: a first part and a second part, which are respectively fitted onto the stator single piece from both ends.

[0014] Optionally, the wire frame is provided with an opening, and the lead end can be inserted through the opening.

[0015] Compared with the prior art, the above-mentioned one or more technical solutions in the monolithic high-efficiency winding module provided by the present invention have at least one of the following technical effects:

[0016] By using a single-layer insulation layer plus a copper foil layer instead of the existing enameled wire for winding, thickness is saved. At the same time, the copper foil has a flat rectangular cross-section, which can fit tightly against the groove wall of the winding position, filling almost without gaps and achieving a high copper filling rate, thereby increasing space utilization and resulting in higher motor efficiency and power density. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this utility model, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the conductor structure of the present invention.

[0019] Figure 2 This is a schematic diagram of the layered structure of the conductor of the present invention.

[0020] Figure 3 A schematic diagram of the structure of the present invention.

[0021] Figure 4 This is a schematic diagram of the exploded structure of the present invention.

[0022] Figure 5 This is a schematic diagram of the combined structure of the present invention.

[0023] The following are the labeling elements in the figure:

[0024] 100. Stator unit; 110. Connecting surface; 111. Connecting groove; 112. Connecting protrusion;

[0025] 200. Conductor; 210. Copper foil layer; 211. Eddy current suppression groove; 212. Lead end; 220. Insulation layer.

[0026] 300, wire frame; 310, winding position; 311, clearance position; 320, first blocking part; 330, second blocking part; 340, connecting part; 350, gap; 360, opening; 370, first split part; 380, second split part. Detailed Implementation

[0027] The embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the embodiments of the present invention, and should not be construed as limiting the present invention.

[0028] In the description of the embodiments of this utility model, it should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings. They are only for the convenience of describing the embodiments of this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0029] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of embodiments of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0030] In this embodiment of the invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this embodiment of the invention according to the specific circumstances.

[0031] In one embodiment of the present invention, according to Figure 1-5 As shown, it includes a stator single piece 100; a wire frame 300 is sleeved on the stator single piece 100, the wire frame 300 is provided with a winding position 310, and a wire 200 is wound on the winding position 310. The wire 200 includes a copper foil layer 210 and an insulating layer 220; the insulating layer 220 is pressed onto the copper foil layer 210.

[0032] Specifically, by setting a single-layer insulation layer 220 plus a copper foil layer 210 to replace the existing enameled wire for winding, the thickness is saved. At the same time, the copper foil has a flat rectangular cross-section, which can closely fit the groove wall of the winding position 310, filling it with almost no gaps 350, resulting in a high copper filling rate, thereby increasing the space utilization rate and making the motor efficiency and power density higher.

[0033] Furthermore, the present invention can be used on motors with fewer than 25 turns.

[0034] Furthermore, the insulating layer 220 is located on top of the copper foil layer 210. When the copper foil layer 210 is wound, the insulating layer 220 can isolate the copper foil layer 210 from contact with the layer, thereby blocking the passage.

[0035] Furthermore, the wire frame 300 is a split structure, comprising two symmetrical parts: a first split 370 and a second split 380. The first split 370 and the second split 380 are respectively fitted onto the stator single piece 100 from both ends.

[0036] In another embodiment, such as Figure 2 As shown, the copper foil layer 210 has at least one through-hole eddy current suppression groove 211, which is used to prevent eddy current loss. The width of the eddy current suppression groove 211 is 0.02 to 0.3 mm. The eddy current suppression groove 211 is filled with insulating glue, which can completely block the conductive path within the eddy current suppression groove 211.

[0037] Specifically, the eddy current suppression groove 211 divides the continuous copper foil conductor into multiple independent segments, effectively breaking the closed loop of eddy currents. Furthermore, the groove width is designed within the preferred range of 0.02-0.3 mm, ensuring sufficient conductive cross-sectional area while achieving optimal eddy current suppression. Moreover, the suppression groove is completely filled with insulating adhesive, thoroughly blocking potential conductive paths. This design solves the problem of electric field concentration caused by edge burrs in traditional grooving processes.

[0038] In another embodiment of the invention, according to Figure 3-5 As shown, the copper foil layer 210 is provided with a lead end 212, which is used for electrical connection. The wire frame 300 is provided with an opening 360, and the lead end 212 can be inserted through the opening 360.

[0039] In another embodiment of the invention, according to Figure 3-5 As shown, the wire frame 300 includes a first blocking portion 320 and a second blocking portion 330; the first blocking portion 320 and the second blocking portion 330 are connected by a connecting portion 340, and a winding position 310 is formed between the first blocking portion 320, the second blocking portion 330 and the connecting portion 340, and the wire 200 is wound around the connecting portion 340. Specifically, the first blocking portion 320 and the second blocking portion 330 form a winding position 310 with the connecting portion 340 for the wire 200 to be wound.

[0040] In another embodiment of the invention, according to Figure 3-5As shown, the winding position 310 includes two symmetrically arranged clearance positions 311. After the two stator single pieces 100 are spliced, a gap 350 is formed between the two adjacent clearance positions 311. The width of the gap 350 gradually narrows from the outside to the inside. When the conductor 200 is wound around the wire frame 300, its winding thickness gradually decreases along the narrowing direction of the gap 350, so that the outer surface of the wound conductor 200 matches the contour of the clearance position 311. Specifically, after the conductor 200 is wound, it can fill the irregular gap 350, which can greatly improve the copper filling rate, allowing more turns to be wound, resulting in higher motor efficiency and power density.

[0041] In another embodiment of the invention, according to Figure 1 and 2 As shown, the area of ​​the insulating layer 220 is larger than that of the copper foil layer 210, allowing the insulating layer 220 to completely cover the copper foil layer 210. The edge of the insulating layer 220 extends beyond the boundary of the copper foil layer 210 (0.2-2 mm beyond), forming a reliable covering structure and completely eliminating the risk of exposed copper foil.

[0042] In another embodiment of the invention, according to Figure 1 and 2 As shown, the insulating layer 220 is made of a polymer film or a composite insulating film. The polymer film is one of polyimide, polyester, polyethylene naphthalate, or polytetrafluoroethylene. Different films differ in temperature resistance, dielectric strength, conductivity, and flexibility, with each material having different strengths. Preferably, we use a composite insulating film, which meets the requirements for temperature resistance, dielectric strength, conductivity, and flexibility for use in motors. A composite insulating film comprises the following raw materials by weight percentage: 50-60% polyimide resin, 20-30% boron nitride nanosheets, 10-15% toughening agent, 5-8% adhesion promoter, and 3-5% flame retardant. The adhesion promoter is a silane coupling agent, the toughening agent is polyetheretherketone micropowder, and the flame retardant is a halogen-free phosphate flame retardant.

[0043] Step 1: Pre-dispersion treatment

[0044] Boron nitride nanosheets were mixed with silane coupling agent (KH-550) at a ratio of 10:1 and ultrasonically treated in ethanol solution for 2 hours; then vacuum dried at 80℃ to obtain surface-modified boron nitride filler.

[0045] Step 2: Slurry preparation

[0046] Under nitrogen protection, polyimide resin was dissolved in NMP solvent (solid content 30%); modified boron nitride filler and polyether ether ketone micro powder were added in sequence, and high-speed shear emulsification was carried out at a stirring rate of 10,000 rpm for 1 hour; flame retardant was added, and stirring was continued until the viscosity reached the target.

[0047] Step 3: Casting and film formation

[0048] Coating was performed on copper foil (0.1-0.3 mm thick) using a slot coater, with a wet film thickness of 100 μm. Stepwise temperature curing was used: first, curing at 80℃ for 30 min, then increasing the temperature to 150℃ and curing for 1 h, and finally, curing at 250℃ for 2 h under a nitrogen atmosphere. Before winding, the surface activity was enhanced by plasma treatment under an argon atmosphere.

[0049] In another embodiment of the invention, according to Figure 3-5 As shown, the stator single piece 100 includes a connecting surface 110; the two ends of the connecting surface 110 are respectively provided with connecting grooves 111 and connecting protrusions 112. When two stator single pieces 100 are spliced, the connecting protrusion 112 of one stator single piece 100 is inserted into the connecting groove 111 of the other stator single piece 100. Specifically, multiple stator single pieces 100 can be spliced ​​together through the connecting grooves 111 and connecting protrusions 112.

[0050] The above description, in conjunction with specific preferred embodiments, provides a further detailed explanation of this utility model. It should not be construed that the specific implementation of this utility model is limited to these descriptions. For those skilled in the art, the architectural form of this utility model can be flexibly varied without departing from its concept, and a series of products can be derived. Any simple deductions or substitutions should be considered as falling within the patent protection scope defined by the submitted claims.

Claims

1. A single-piece high-efficiency winding module, characterized in that, The device includes a stator lamination; a wire frame is fitted onto the stator lamination, the wire frame has winding positions, and a conductor is wound around the winding positions. The conductor includes a copper foil layer and an insulating layer; the insulating layer is pressed onto the copper foil layer; at least one through-hole eddy current suppression groove is provided on the copper foil layer to prevent eddy current loss; the eddy current suppression groove is filled with insulating adhesive, which completely blocks the conductive path within the eddy current suppression groove.

2. The single-piece high-efficiency winding module of claim 1, wherein, The width of the eddy current suppression groove is 0.02 to 0.3 mm.

3. The single-piece high-efficiency winding module of claim 1, wherein, The copper foil layer is provided with lead-in terminals, which are used for electrical connections.

4. The single-piece high-efficiency winding module of claim 1, wherein, The wire frame includes a first blocking part and a second blocking part; the first blocking part and the second blocking part are connected by a connecting part, and the winding position is formed between the first blocking part, the second blocking part and the connecting part, and the wire is wound around the connecting part.

5. The single-piece high-efficiency winding module of claim 4, wherein, The winding position includes two symmetrically arranged clearance positions; after the two stator pieces are spliced ​​together, a gap is formed between the two adjacent clearance positions, and the width of the gap gradually narrows from the outside to the inside. When the wire is wound around the wire frame, its winding thickness gradually decreases along the narrowing direction of the gap, so that the outer surface of the wound wire matches the contour of the clearance position.

6. The single-piece high-efficiency winding module according to any one of claims 1-5, wherein, The area of ​​the insulating layer is larger than the area of ​​the copper foil layer, so that the insulating layer can completely cover the copper foil layer.

7. The single-piece high-efficiency winding module of claim 1, wherein, The insulating layer is made of polymer insulating film or composite insulating film.

8. The single-piece high-efficiency winding module according to claim 4, characterized in that, The stator single piece includes a connecting surface; the two ends of the connecting surface are respectively provided with a connecting groove and a connecting protrusion. When two stator single pieces are spliced ​​together, the connecting protrusion of one stator single piece is inserted into the connecting groove of the other stator single piece.

9. The single-piece high-efficiency winding module of claim 3, wherein, The wire frame is a split structure, comprising two symmetrically arranged parts: a first part and a second part. The first part and the second part are respectively fitted onto the stator single piece from both ends.

10. The single-piece high-efficiency winding module of claim 9, wherein, The wire frame is provided with an opening, and the lead end can be inserted through the opening.

Images