Motor copper foil leading-out wire structure

Abstract

The utility model relates to the technical field of copper foil welding, in particular to a motor copper foil outgoing line structure. The motor copper foil leading-out wire structure provided by the utility model is formed by welding a copper foil winding leading-out wire, a gap of the leading-out wire and a copper foil lap joint area are uniformly filled with welding flux, the sectional area of the welding position is larger than 150% of the sectional area of the copper foil, and the welding length of the leading-out wire in the axial direction is 70%-100% of the width of the copper foil. The length of a copper foil lap joint area is 30%-70% of the total width of the leading-out wire in the radial direction, the number of winding turns of the copper foil completely winding the leading-out wire is 1-3, the contact area of the copper foil and the leading-out wire is large, a winding assembly is compact in structure, the lap joint range is large, the welding spot strength after welding forming is high, no welding seam exists on the outer side of the copper foil, the structural appearance flatness is high, and the problems of burn-through, deformation and the like do not exist. And copper foil winding is facilitated, and the slot fullness rate of the motor is effectively improved.

Description

A copper foil lead wire structure for motors Technical Field

[0001] This utility model relates to the field of copper foil welding technology, and in particular to a structure for copper foil lead wires of motors. Background Technology

[0002] Currently, the rapid development of the new energy vehicle industry has placed higher demands on the power density and performance of drive motors.

[0003] High-power-density motors can deliver greater power output in a smaller size and weight, thereby improving vehicle performance, range, and energy efficiency. Using copper foil as the armature coil material is one of the important means to improve motor performance. Copper foil has excellent conductivity and high mechanical strength, which can significantly improve the slot fill factor of the motor, thereby further improving power density and torque density.

[0004] However, copper foil also faces some technical challenges in practical applications. Copper foil is wide, thin, and lacks flexibility, making it difficult to twist, which requires a significant amount of space during motor assembly. To achieve flexibility in bending and installation, additional lead wires are usually welded. However, current copper foil lead wire welding technology suffers from insufficient contact area between the copper foil and the lead wire, poor weld joint stability, uneven weld shape, and copper foil deformation after welding. These problems can further lead to insufficient current carrying capacity, motor overheating, weld joint detachment, and poor winding quality, affecting the overall performance of the motor.

[0005] Therefore, how to improve the structural stability, current carrying capacity, and service life of copper foil welding leads remains a problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0006] To address the technical problem of improving the structural stability, current carrying capacity, and service life of copper foil welded lead wires, this utility model provides a motor copper foil lead wire structure, which is formed by welding copper foil wound into lead wires, with solder evenly filling the area around the lead wires and the overlapping area of ​​the copper foils.

[0007] Among them, the cross-sectional area of ​​the weld is greater than 150% of the cross-sectional area of ​​the copper foil;

[0008] One end of the lead wire is connected to the copper foil winding, and the other end is connected to the output terminal.

[0009] In one embodiment, the thickness of the copper foil is 0.02 mm to 1 mm.

[0010] In one embodiment, the lead wire is a copper wire with a specification of φ0.03 ~ φ1.1 and a number of strands ≥1.

[0011] Furthermore, when the number of copper wire strands is ≥5, the multiple copper wires are arranged in a rectangular array on the surface of the copper foil, with the long side of the rectangular array parallel to the side of the copper foil and the short side perpendicular to the side of the copper foil.

[0012] Furthermore, the rectangular array has 2 to 4 layers of copper wire arranged on its short side.

[0013] In one embodiment, the solder is HL204 or HL205.

[0014] In one embodiment, the axial welding length of the lead wire is 70% to 100% of the width of the copper foil.

[0015] In one embodiment, the overlap area of ​​the copper foil is 30% to 70% of the total radial width of the lead wire.

[0016] In one embodiment, the number of turns of the copper foil fully wound around the lead wire is 1 to 3 turns.

[0017] In one embodiment, when the motor copper foil lead wire structure serves as the inlet and outlet ends respectively, the lead wires are located on the inner and outer sides of the copper foil respectively.

[0018] Compared with the prior art, the present invention has the following beneficial effects:

[0019] The copper foil lead wire structure for motors provided by this utility model is formed by winding copper foil into a lead wire and welding it. The copper foil has a large contact area with the lead wire, and the solder evenly fills the gaps in the lead wire and the overlapping area of ​​the copper foil. The cross-sectional area of ​​the weld is greater than 150% of the cross-sectional area of ​​the copper foil, effectively preventing the weld from becoming a bottleneck in current conduction. Furthermore, the copper foil is completely wound around the lead wire 1 to 3 times, and the length of the copper foil overlapping area is 30% to 70% of the radial width of the lead wire. The winding assembly has a dense structure, a large overlapping range, high weld strength after welding, no weld seams on the outer side of the copper foil, high structural flatness, and no surface quality problems such as burn-through or deformation. After the copper foil winding is completed, the motor slot fill factor is high, effectively improving the motor power density. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 is a schematic diagram of the copper foil winding lead wire assembly provided in Embodiment 1 of this utility model;

[0022] Figure 2 is a schematic diagram of the motor copper foil lead wire structure provided in Embodiment 1 of this utility model.

[0023] Figure label:

[0024] 10 - Copper foil; 20 - Lead wire; 30 - Solder. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0026] In the description of this utility model, it should be noted that the terms "upper", "lower", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing 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.

[0027] Example 1

[0028] This embodiment provides a copper foil lead wire structure for a motor. As shown in Figure 1, the lead wire 20 is wound around the copper foil 10 and welded together as shown in Figure 2. Solder 30 is uniformly filled around the lead wire 20 and the overlapping area of ​​the copper foil 10. The cross-sectional area of ​​the weld is greater than 414% of the cross-sectional area of ​​the copper foil.

[0029] The thickness of the copper foil 10 is 0.1 mm.

[0030] The lead wire 20 is a copper wire with a specification of φ0.8 and 16 strands. The multiple copper wires are arranged in a rectangular array on the surface of the copper foil 10. The long side of the rectangular array is parallel to the side of the copper foil 10, and the short side is perpendicular to the side of the copper foil 10. Two layers of copper wires are arranged on the short side of the rectangular array.

[0031] The solder 30 is HL204.

[0032] The axial welding length of the lead wire 20 is 100% of the width of the copper foil 10;

[0033] During the actual welding process, the lead wire and the copper foil have a large contact area, which ensures that the cross-sectional area of ​​the weld is larger than that of the copper foil, thereby preventing the weld from becoming a bottleneck in current conduction.

[0034] The overlap length of the copper foil 10 is 50% of the total radial width of the lead wire 20;

[0035] During the actual welding process, it can ensure the structural stability of the component with copper foil 10 wound with lead wire 20, and also provide sufficient welding area to improve the stability of the solder joint and the uniformity of solder distribution.

[0036] The copper foil 10 is wound with the lead wire 20 in one turn.

[0037] When the motor copper foil lead wire structure is used as the input terminal, the lead wire 20 is located inside the copper foil 10, that is, on the center side of the copper foil winding; when the motor copper foil lead wire structure is used as the output terminal, the lead wire 20 is located outside the copper foil 10, that is, on the periphery side of the copper foil winding.

[0038] Example 2

[0039] This embodiment provides a copper foil lead wire structure for an electric motor, which is formed by winding copper foil 10 around lead wire 20 and welding it. Solder 30 is uniformly filled in the area around lead wire 20 and the overlapping area of ​​copper foil 10; wherein, the cross-sectional area of ​​the weld is greater than 154% of the cross-sectional area of ​​copper foil.

[0040] In this embodiment, the thickness of the copper foil 10 is 0.3 mm.

[0041] In this embodiment, the lead wire 20 is a copper wire with a specification of φ0.8 and 16 strands. The multiple copper wires are arranged in a rectangular array on the surface of the copper foil 10. The long side of the rectangular array is parallel to the side of the copper foil 10, and the short side is perpendicular to the side of the copper foil 10. Two layers of copper wires are arranged on the short side of the rectangular array.

[0042] In this embodiment, the solder 30 is HL205.

[0043] In this embodiment, the axial welding length of the lead wire 20 is 100% of the width of the copper foil 10.

[0044] In this embodiment, the length of the overlapping area of ​​the copper foil 10 is 50% of the total radial width of the lead wire 20.

[0045] In this embodiment, the copper foil 10 is wound with the lead wire 20 in one turn.

[0046] In this embodiment, when the motor copper foil lead wire structure is used as the input end, the lead wire 20 is located inside the copper foil 10, that is, the center side of the copper foil winding; when the motor copper foil lead wire structure is used as the output end, the lead wire 20 is located outside the copper foil 10, that is, the periphery side of the copper foil winding.

[0047] Although this document frequently uses terms such as copper foil, lead wire, winding, welding, overlapping, deformation, and burn-through, the possibility of using other terms is not excluded. These terms are used merely for the convenience of describing and explaining the essence of this invention; interpreting them as any additional limitation would contradict the spirit of this invention.

[0048] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model.

Claims

1. A structure for copper foil lead wires in an electric motor, characterized in that: The copper foil (10) is wound around the lead wire (20) and welded together. Solder (30) is evenly filled around the lead wire (20) and the overlapping area of ​​the copper foil (10). The cross-sectional area of ​​the weld is greater than 150% of the cross-sectional area of ​​the copper foil.

2. The motor copper foil lead wire structure according to claim 1, characterized in that: The thickness of the copper foil (10) is 0.02 mm to 1 mm.

3. The motor copper foil lead wire structure according to claim 1, characterized in that: The lead wire (20) is a copper wire with a specification of φ0.03 ~ φ1.1 and a number of strands ≥1.

4. The motor copper foil lead wire structure according to claim 3, characterized in that: When the number of copper wire strands is ≥5, the multiple copper wire strands are arranged in a rectangular array on the surface of the copper foil (10), with the long side of the rectangular array parallel to the side of the copper foil (10) and the short side perpendicular to the side of the copper foil (10).

5. The motor copper foil lead wire structure according to claim 4, characterized in that: The rectangular array has 2 to 4 layers of copper wire arranged on its short side.

6. The motor copper foil lead wire structure according to claim 1, characterized in that: The solder (30) is HL204 or HL205.

7. The motor copper foil lead wire structure according to claim 1, characterized in that: The axial welding length of the lead wire (20) is 70% to 100% of the width of the copper foil (10).

8. The motor copper foil lead wire structure according to claim 1, characterized in that: The overlap length of the copper foil (10) is 30% to 70% of the total radial width of the lead wire (20).

9. The motor copper foil lead wire structure according to claim 1, characterized in that: The number of turns of the copper foil (10) completely wound around the lead wire (20) is 1 to 3.

10. The motor copper foil lead wire structure according to claim 1, characterized in that: When the copper foil lead wire structure of the motor is used as the inlet and outlet respectively, the lead wire (20) is located on the inner and outer sides of the copper foil (10).

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