Stator assembly, stator, electric machine and household appliance

Abstract

This utility model discloses a stator assembly, a stator, a motor, and a household appliance, relating to the field of stator technology. The stator assembly includes: a stator core, the stator core comprising multiple core units arranged circumferentially, each core unit including connected teeth and yokes; and a plastic coating body, the plastic coating body including connected covering parts and mounting parts, the covering parts covering the outside of the stator core, and multiple mounting parts spaced circumferentially. The line connecting the center of the mounting part to the center of the circumference is a first connecting line, and the line connecting the intersection of two adjacent yokes to the center of the circumference is a second connecting line. The angle between the second connecting line closest to the first connecting line and the first connecting line is α, and the number of core units is Z, where α < (180° / Z). The technical solution of this utility model reduces high-frequency noise and improves the processing accuracy of core unit blanking in a single operation.

Description

Technical Field

[0001] This utility model relates to the field of stator technology, and in particular to a stator assembly, a stator, a motor, and a household appliance. Background Technology

[0002] With the development of motor technology, especially the widespread application of high-efficiency, high-power-density motors in various precision equipment and household appliances, higher requirements have been placed on noise and vibration control during motor operation. As one of the core components of a motor, the stator's structural design directly affects the motor's electromagnetic performance and mechanical vibration characteristics. Among these, high-frequency noise has become a significant factor affecting the user experience of motors.

[0003] Currently, stators typically consist of a stator core and a plastic-coated body, with the plastic-coated body used to fix the stator core and provide electrical insulation. However, in traditional structural designs, the distribution of the stator core along the circumference of the plastic-coated body is unreasonable, resulting in significant high-frequency noise. Furthermore, in order to facilitate easier separation of the stator core laminations from the sheet metal, achieving single-pass blanking and improving silicon steel utilization, the machining accuracy of the stator core is compromised. Utility Model Content

[0004] The main objective of this invention is to provide a stator assembly, a stator, a motor, and a household appliance, aiming to solve at least one of the aforementioned technical problems.

[0005] To achieve the above objectives, this utility model provides a stator assembly, the stator assembly comprising:

[0006] Stator core, the stator core comprising multiple core units arranged circumferentially, each core unit comprising connected teeth and a yoke; and

[0007] The plastic-coated body includes a covered portion and a mounting portion connected together. The covered portion covers the outside of the stator core. Multiple mounting portions are spaced apart along the circumference. The line connecting the center of the mounting portion to the center of the circumference is a first connecting line. The line connecting the intersection of two adjacent yoke portions to the center of the circumference is a second connecting line. The angle between the second connecting line closest to the first connecting line and the first connecting line is α. The number of core units is Z, where α < (180° / Z).

[0008] In one implementation, α < (90° / Z).

[0009] In one embodiment, the thickness of the plastic-coated body in the intersection region of two adjacent yokes is L, where L ≥ 1.5 mm.

[0010] In one embodiment, the plurality of core units are separate structures; or, the plurality of core units are integral structures.

[0011] In one embodiment, when the plurality of core units are an integral structure, the yokes of two adjacent core units are at least partially fixedly connected.

[0012] In one embodiment, the yoke is configured to bend so that the plurality of core units are arranged in a ring around it.

[0013] In one embodiment, the outer peripheral surface of the yoke of each core unit is provided with an easily separable structure.

[0014] In one embodiment, the separable structure is configured as a groove, the groove being disposed on the outer peripheral surface of the yoke and corresponding to the tooth; and / or, the separable structure is configured as a notch, two adjacent yokes forming a deformation groove on the side surface facing the tooth, the notch being disposed on the outer peripheral surface of the yoke and close to the deformation groove.

[0015] In one embodiment, the maximum thickness of the yoke is Hs, and the maximum width of the teeth is Wt;

[0016] The maximum depth of the groove is Hm, the maximum width of the groove is Lm, 0.02≤Hm / Hs≤0.35, 0.1≤Lm / Wt≤0.77; and / or, the maximum depth of the notch is Hz, the maximum width of the notch is Lz, 0.01≤Hz / Hs≤0.15; 0.05≤Lz / Wt≤0.15.

[0017] To achieve the above objectives, this utility model provides a stator, which includes a winding and the stator assembly described above, wherein the winding is wound around the tooth portion.

[0018] To achieve the above objectives, this utility model provides an electric motor, which includes a rotor and a stator as described above, wherein the stator core forms a rotor hole; and the rotor is rotatably disposed in the rotor hole.

[0019] To achieve the above objectives, this utility model provides a household appliance, which includes the motor described above.

[0020] In this application's technical solution, the mounting portion protrudes from the outer periphery of the covering portion. In the region corresponding to the mounting portion, the radial thickness of the plastic-coated body is significantly increased, effectively enhancing the material volume and structural stiffness of this region, thereby strengthening the vibration absorption and load-bearing capacity of the plastic-coated body in this area. In existing stator structures, the intersection area between two adjacent yokes is usually a relatively weak point in mechanical strength. During motor operation, especially under high-frequency conditions, stress concentration is prone to occur in this intersection area, leading to increased local vibration and the generation and propagation of high-frequency noise. Therefore, in this application, the angle α is set to be less than 180° / Z. This means that the second connecting line is closer to the first connecting line, and the intersection point of the two yokes corresponding to the second connecting line closer to the first connecting line is closer to the mounting portion. Because this intersection point is closer to the mounting section, and the area corresponding to the mounting section itself has a larger radial thickness and higher structural stiffness, it can effectively support the weak intersection area, improving its overall structural strength and stability. This prevents local stress concentration, better absorbs and disperses the vibration stress generated during motor operation, reduces vibration noise, and enhances the vibration absorption effect of the plastic coating, thereby effectively suppressing high-frequency noise. It is understood that this application rationally arranges the core units based on the radial thickness of the plastic coating, optimizing the structural strength of the main vibration areas. Without adding additional noise reduction components, it effectively improves the overall quietness and operational stability of the motor. Attached Figure Description

[0021] 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 only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of the structure of an embodiment of the stator assembly of this utility model;

[0023] Figure 2 This is a three-dimensional structural diagram of an embodiment of the stator assembly of this utility model;

[0024] Figure 3 This is a schematic diagram of another embodiment of the stator assembly of this utility model;

[0025] Figure 4 This is a schematic diagram of the stator core arrangement in an embodiment of the stator assembly of this utility model;

[0026] Figure 5 This is a schematic diagram of the core unit in an embodiment of the stator assembly of this utility model;

[0027] Figure 6 This is a structural schematic diagram of an embodiment of the motor of this utility model.

[0028] Explanation of icon numbers:

[0029] 100. Stator core; 110. Core unit; 111. Tooth; 112. Yoke; 113. Deformation groove; 120. Easy-to-separate structure; 121. Groove; 122. Notch; 200. Plastic coating; 210. Covering part; 220. Mounting part; 300. Rotor.

[0030] The realization of the purpose, functional features and advantages of this utility model will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0031] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the embodiments of the present utility model.

[0032] It should be noted that all directional indicators (such as up, down, left, right, front, back, etc.) in this utility model embodiment are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicator will also change accordingly.

[0033] Furthermore, in the embodiments of this utility model, descriptions involving "first," "second," etc., are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of the embodiments of this utility model, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0034] In this embodiment of the invention, unless otherwise explicitly specified and limited, the terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. 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.

[0035] Furthermore, the technical solutions of the various embodiments of this utility model can be combined with each other, but only if they are based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the protection scope claimed by the embodiments of this utility model.

[0036] Currently, a stator typically consists of a stator core and a plastic-coated body, with the plastic-coated body used to fix the stator core and provide electrical insulation. However, in traditional structural designs, the distribution of the stator core along the circumference of the plastic-coated body is unreasonable, resulting in significant high-frequency noise.

[0037] In view of this, the present invention provides a stator assembly, a stator, a motor, and a household appliance. The iron core units are arranged reasonably according to the radial thickness of the plastic coating, thereby optimizing the structural strength of the main vibration area. Without adding additional noise reduction components, the overall quietness and smoothness of the motor are effectively improved.

[0038] To better understand the above technical solution, the following detailed explanation is provided in conjunction with the accompanying drawings.

[0039] like Figures 1 to 3 As shown in the figure, this utility model embodiment proposes a stator assembly, the stator assembly comprising:

[0040] A stator core 100 includes multiple core units 110 arranged circumferentially, meaning the core units 110 are connected end-to-end to form a ring. Each core unit 110 includes connected teeth 111 and a yoke 112, wherein the teeth 111 are used for winding a coil, and the yoke 112 is located at the end of the teeth 111 facing away from the center of the ring. When multiple core units 110 are connected end-to-end, the yokes 112 in adjacent core units 110 intersect; and

[0041] The plastic-coated body 200 includes a covered portion 210 and a mounting portion 220 connected to each other. The covered portion 210 covers the outside of the stator core 100, and multiple mounting portions 220 are spaced apart circumferentially. Specifically, the covered portion 210 is used to fix the stator core 100 and other parts of the stator, and the mounting portion 220 is used to fix the stator assembly in a predetermined position. The line connecting the center of the mounting portion 220 to the center of the circumference is a first connecting line, and the line connecting the intersection of two adjacent yoke portions 112 to the center of the circumference is a second connecting line. The angle between the second connecting line closest to the first connecting line and the first connecting line is α, and the number of core units 110 is Z, where α < (180° / Z). This allows the second connecting lines to be closer to the first connecting line, improving the structural strength of the intersection area of ​​the two yoke portions 112 corresponding to the second connecting line, dispersing stress, and reducing vibration.

[0042] In this embodiment, the mounting portion 220 protrudes from the outer periphery of the covering portion 210. In the region corresponding to the mounting portion 220, the radial thickness of the plastic-coated body 200 is significantly increased, effectively improving the material volume and structural rigidity of this region, thereby enhancing the vibration absorption and load-bearing capacity of the plastic-coated body 200 in this region. In existing stator structures, the intersection area between two adjacent yoke portions 112 is usually a relatively weak mechanical location. During motor operation, especially under high-frequency conditions, stress concentration is prone to occur in this intersection area, leading to increased local vibration and the generation and propagation of high-frequency noise. Therefore, in this application, the angle of α is set to less than 180° / Z. That is, the second connecting line is closer to the first connecting line, meaning the intersection point of the two yoke portions 112 corresponding to the second connecting line closer to the first connecting line will be closer to the mounting portion 220. Because the intersection point is closer to the mounting section 220, and the area corresponding to the mounting section 220 itself has a larger radial thickness and higher structural stiffness, it can effectively support the weak intersection area, improve its overall structural strength and stability, prevent the occurrence of local stress concentration, better absorb and disperse the vibration stress generated during motor operation, reduce vibration noise, and improve the vibration absorption effect of the plastic coating 200, thereby effectively suppressing high-frequency noise. It is understood that this application rationally arranges the core units 110 based on the radial thickness of the plastic coating 200, achieving structural strength optimization of the main vibration areas, and effectively improving the overall quietness and operational stability of the motor without adding additional noise reduction components.

[0043] In one embodiment of this invention, α < (90° / Z). Specifically, the smaller the angle α, the better the noise suppression effect, and the more intersection areas of the yokes 112 covered by a single mounting part 220 can be increased. That is, the number of intersection points of two adjacent yokes 112 in the corresponding area of ​​the mounting part 220 will increase. It can be understood that when the angle α decreases, the corresponding intersection point area is more concentrated, and more yoke intersection points can be set in the area corresponding to the mounting part 220. With the concentration of the intersection point area, the effective vibration absorption area covered by the mounting part 220 is relatively larger, which can absorb high-frequency vibration energy more efficiently. Moreover, since each mounting part 220 can support multiple weak connection areas at the same time, the number of mounting parts 220 required can be reduced, reducing mold complexity and assembly difficulty. In this embodiment, α < (90° / Z) can balance the effect of noise suppression and the effect of enhancing the structural strength of the intersection areas of multiple adjacent yokes 112.

[0044] In one embodiment of this utility model, the thickness of the plastic-coated body 200 at the intersection region of two adjacent yokes 112 is L, where L ≥ 1.5 mm. During motor operation, especially under high-frequency conditions, the vibration energy generated inside the stator core 100 is transmitted to the plastic-coated body 200 through magnetostriction, electromagnetic force fluctuations, and other pathways. Therefore, the thickness of the plastic-coated body 200 at key locations directly affects its vibration absorption performance. Generally speaking, under the premise of unchanged material properties, the greater the thickness of the plastic-coated body 200, the stronger its ability to absorb and attenuate vibration energy, thereby helping to reduce the overall vibration level and noise radiation of the motor. In this embodiment, the thickness L of the plastic-coated body 200 corresponding to the intersection region of two adjacent yokes 112 is set to be no less than 1.5 mm. This not only increases the material volume in this region and enhances the vibration absorption capacity of the plastic-coated body 200, but also helps to improve the overall structural strength of this region, preventing structural cracking caused by local stress concentration. Optionally, L can be 1.5 mm, 2 mm, 2.5 mm, 3 mm, etc., and can be selected according to actual usage needs. No limitation is made here.

[0045] In one embodiment of this utility model, the plurality of core units 110 are of a split structure. This means that each core unit 110 is independently configured and then assembled together to form the stator core 100. During assembly, the yokes 112 of adjacent core units 110 can be fixed together by welding, protrusion, or adhesive bonding, or by connecting bridges, or by an insulating frame. The split core units 110 facilitate manufacturing and assembly; alternatively, the plurality of core units 110 can be of an integral structure, meaning that multiple core units 110 are integrated into one unit through stamping or casting to form an integral stator core 100 structure, which is beneficial for improving the overall mechanical strength and structural stability of the stator core 100.

[0046] In one embodiment of this utility model, when the multiple core units 110 are an integral structure, the yokes 112 of two adjacent core units 110 are at least partially fixedly connected. This enhances the overall mechanical strength and structural stability of the stator core 100, and allows for better mechanical support and load transfer paths between adjacent core units 110, thereby effectively suppressing vibration. Specifically, the yokes 112 of two adjacent core units 110 can be completely or partially fixedly connected together, allowing for flexible selection of a suitable connection method based on actual needs, thus reducing manufacturing costs.

[0047] In one embodiment of this utility model, the yoke 112 is configured to bend so that the plurality of core units 110 are arranged in a ring. It is understood that in this embodiment, the stator core 100 is a strip stator core 100, which, after being formed, is bent by the yoke 112 to form a ring-shaped stator core 100. That is, the plurality of core units 110 can be bent and deformed to a certain extent along the yoke 112, thereby bending the originally linearly arranged strip stator cores 100 as a whole and forming a ring-shaped stator core 100. Compared with the traditional ring-shaped laminated structure, the strip structure is easier to stamp, reducing the complexity of the stamping die and improving production efficiency and material utilization. Moreover, by controlling the bending angle and bending direction of the yoke 112, the overall inner diameter, outer diameter, and tooth distribution of the stator core 100 can be easily adjusted, thereby adapting to motors with different pole numbers, slot numbers, and power ratings. Optionally, the stator core 100 is made of silicon steel sheet by stamping.

[0048] In one embodiment of this utility model, reference is made to Figure 3Each core unit 110 has an easily separable structure 120 on the outer peripheral surface of its yoke 112. Specifically, in the traditional stator core 100 stamping manufacturing, it is usually processed by integral blanking and grooving. Since a certain connection structure needs to be maintained between multiple core units 110 to facilitate subsequent bending and assembly, problems such as incomplete blanking, large springback, and material adhesion often occur during the stamping process, which adversely affect the stamping accuracy. To address this, this embodiment provides an easily separable structure 120. The easily separable structure 120 refers to the design of specific structural forms, such as grooves 121, scribe lines, thinning areas, or locally weakened areas, at the connection point between the yoke 112 and the sheet metal during the stamping die processing. This reduces the connection strength between the stator core 100 and the raw material sheet after stamping, allowing the stator core 100 sheets to be separated from the raw material sheet more easily, thereby achieving effective separation of each core unit 110 from the sheet metal in a single blanking operation.

[0049] In one embodiment of this utility model, reference is made to Figure 3 and Figure 4 The easily separable structure 120 is configured as a groove 121, which is located on the outer peripheral surface of the yoke 112 and corresponds to the tooth 111; and / or, the easily separable structure 120 is configured as a notch 122, where two adjacent yokes 112 form a deformation groove 113 on the surface facing the tooth 111. The deformation groove 113 provides deformation space for bending of the yoke 112, and the notch 122 is located on the outer peripheral surface of the yoke 112 and close to the deformation groove 113. Specifically, the easily separable structure 120, configured as a groove 121 and / or a notch 122, can reduce the connection length between the yoke 112 and the raw material sheet, making it easier to separate the stator lamination from the sheet, achieving blanking in one step, preventing adhesion problems, and improving stamping accuracy. Moreover, the notch 122 and the deformation groove 113 correspond to each other, facilitating bending of two adjacent yokes 112. Optionally, the groove 121 can be a square groove, and the notch 122 can be a V-shaped opening or a semi-circular opening. In one embodiment, either the groove 121 or the notch 122 can be provided. Of course, in other embodiments, both the groove 121 and the notch 122 can be provided simultaneously.

[0050] In one embodiment of this utility model, reference is made to Figure 5 The maximum thickness of the yoke 112 is Hs, and the maximum width of the tooth 111 is Wt;

[0051] The maximum depth of the groove 121 is Hm, and the maximum width of the groove 121 is Lm, with 0.02≤Hm / Hs≤0.35 and 0.1≤Lm / Wt≤0.77. This ensures the overall structural strength of the stator core 100 while facilitating material cutting. And / or, the maximum depth of the notch 122 is Hz, and the maximum width of the notch 122 is Lz, with 0.01≤Hz / Hs≤0.15 and 0.05≤Lz / Wt≤0.15. This ensures the overall structural strength of the stator core 100 while facilitating material cutting.

[0052] Specifically, before stamping the stator core 100, it is usually necessary to lay out the raw material plates, referring to... Figure 4 This maximizes the use of the sheet metal area and reduces waste. By defining the above-mentioned range, in two adjacent rows of stator cores 100, the notch 122 of one row of stator cores 100 and the groove 121 of the other row of stator cores 100 are opposite each other, further facilitating material unloading.

[0053] To achieve the above objectives, this utility model provides a stator, which includes a winding and the stator assembly described above, wherein the winding is wound around the tooth portion. Specifically, the specific structure of the stator assembly refers to the above embodiment. Since this stator adopts all the technical solutions of the above embodiments, it has at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be elaborated here.

[0054] To achieve the above objectives, this utility model provides an electric motor, referring to... Figure 6 The motor includes a rotor 300 and the stator described above, with the stator core forming a rotor hole; the rotor 300 is rotatably disposed in the rotor hole. Specifically, the specific structure of the stator refers to the above embodiment. Since this motor adopts all the technical solutions of the above embodiments, it has at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be elaborated here.

[0055] To achieve the above objectives, this utility model provides a household appliance comprising the motor described above. Specifically, the motor's structure is as described in the above embodiments. Since this household appliance employs all the technical solutions described in the above embodiments, it possesses at least all the beneficial effects brought about by the technical solutions described in the above embodiments, and will not be elaborated upon further here. Optionally, the household appliance may be an air conditioner or other electrical equipment, and is not limited thereto.

[0056] The above description is merely an exemplary embodiment of the present utility model and does not limit the scope of protection of the present utility model embodiments. Any equivalent structural transformations made under the technical concept of the present utility model using the description and drawings of the present utility model embodiments, or direct / indirect applications in other related technical fields, are included within the scope of protection of the present utility model embodiments.

Claims

1. A stator assembly characterized by, The stator assembly includes: Stator core, the stator core comprising multiple core units arranged circumferentially, each core unit comprising connected teeth and a yoke; and The plastic-coated body includes a covered portion and a mounting portion connected together. The covered portion covers the outside of the stator core. Multiple mounting portions are spaced apart along the circumference. The line connecting the center of the mounting portion to the center of the circumference is a first connecting line. The line connecting the intersection of two adjacent yoke portions to the center of the circumference is a second connecting line. The angle between the second connecting line closest to the first connecting line and the first connecting line is α. The number of core units is Z, where α < (180° / Z).

2. The stator assembly of claim 1, wherein, α < (90° / Z).

3. The stator assembly of claim 1, wherein, The thickness of the plastic-coated body in the intersection region of two adjacent yokes is L, where L ≥ 1.5 mm.

4. The stator assembly of claim 1, wherein, The multiple core units are of a separate structure; or, the multiple core units are of a single integrated structure.

5. The stator assembly of claim 4, wherein, When multiple core units are integral structures, the yokes of two adjacent core units are at least partially fixedly connected.

6. The stator assembly of claim 4, wherein, The yoke is configured to be flexible so that the plurality of core units are arranged in a ring around it.

7. A stator assembly as claimed in claim 5 or 6, wherein, The outer peripheral surface of the yoke of each core unit is provided with an easy-to-separate structure.

8. The stator assembly of claim 7, wherein, The easily separable structure is configured as a groove, which is located on the outer peripheral surface of the yoke and corresponds to the tooth; and / or, the easily separable structure is configured as a notch, where two adjacent yokes form a deformation groove on the side surface facing the tooth, and the notch is located on the outer peripheral surface of the yoke and close to the deformation groove.

9. The stator assembly of claim 8, wherein, The maximum thickness of the yoke is Hs, and the maximum width of the tooth is Wt. The maximum depth of the groove is Hm, the maximum width of the groove is Lm, 0.02≤Hm / Hs≤0.35, 0.1≤Lm / Wt≤0.77; and / or, the maximum depth of the notch is Hz, the maximum width of the notch is Lz, 0.01≤Hz / Hs≤0.15; 0.05≤Lz / Wt≤0.

15.

10. A stator characterized by, The stator includes a winding and a stator assembly as described in any one of claims 1 to 9, wherein the winding is wound around the teeth.

11. An electric machine characterized by The motor includes a rotor and a stator as described in claim 10, wherein the stator core forms a rotor hole; the rotor is rotatably disposed in the rotor hole.

12. A domestic appliance characterized in that, The household appliance includes the motor as described in claim 11.

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