An integrally molded insulating frame and scroll compressor

Abstract

This utility model relates to the field of scroll compressor technology, and more particularly to an integrally molded insulating frame and scroll compressor. The integrally molded insulating frame includes multiple toothed insulating members disposed between two adjacent teeth of the stator core. The toothed insulating members cover the sidewalls of the teeth of the stator core and penetrate the stator core axially. An annular disk is disposed at both ends of the multiple toothed insulating members along the axial direction, and the stator core is sandwiched between two annular disks. An annular wall plate is disposed on the annular disk and protrudes axially from the annular disk. The motor windings are arranged on the annular wall plate. The toothed insulating members, the annular disks, and the annular wall plate are integrally molded. This integrally molded insulating frame and scroll compressor can solve the problems of cumbersome installation and easy deformation and loosening of existing stator core insulation structures.

Description

Technical Field

[0001] This application relates to the field of scroll compressor technology, and in particular to an integrally molded insulating frame and a scroll compressor. Background Technology

[0002] Electric motors, as the power source for electrical appliances and various machines, are widely used in various industries, such as the compressor industry.

[0003] The main function of an electric motor is to convert electrical energy into mechanical energy. An electric motor mainly consists of a stator and a rotor. The stator has stator coils, and the rotor has magnets. The rotation of the motor is achieved by the interaction of the magnetic field generated by the magnets and the magnetic field generated when the stator coils are energized. The stator includes a stator core, insulating components, and stator coils. The insulating components are located outside the stator teeth of the stator core, and the stator coils are mounted on the insulating components, which provide insulation between the stator coils and the stator core.

[0004] Currently, with the increasing speed and displacement of scroll compressors, the weight of the moving scroll plate is also constantly increasing, leading to a continuous increase in motor power and current, and consequently, a greater risk of insulation failure. Existing motor stator core insulation typically uses a single upper and lower frame spliced ​​together, or insulating paper wrapped around the stator core, or a single upper and lower frame with insulating paper used for insulation within the stator slots. However, these insulation devices are time-consuming and labor-intensive to install, and are prone to poor withstand voltage and frame deformation after stator winding, as well as loosening and peeling during long-term use. Utility Model Content

[0005] In view of this, the purpose of this application is to provide an integrally molded insulating frame and a scroll compressor to solve the problems of cumbersome installation of the existing stator core insulation structure and its susceptibility to deformation and loosening.

[0006] According to a first aspect of the present invention, an integrally formed insulating frame is provided, wherein the integrally formed insulating frame comprises: a plurality of toothed insulating members disposed between two adjacent teeth of the stator core, the toothed insulating members covering the sidewalls of the teeth of the stator core and penetrating the stator core axially; an annular disk portion disposed at both ends of the plurality of toothed insulating members axially, the stator core being sandwiched between two annular disk portions; and an annular wall plate disposed on the annular disk portion, the annular wall plate protruding axially from the annular disk portion, the windings of the motor being arranged on the annular wall plate; the toothed insulating members, the annular disk portion, and the annular wall plate are integrally formed.

[0007] Preferably, the number of the plurality of toothed insulators is equal to the number of teeth of the stator core, the toothed insulators are arranged in the gap between two adjacent teeth, and the end face of the teeth near the axis of the stator core is exposed in the toothed insulators.

[0008] Preferably, the annular disk portion includes an upper annular disk and a lower annular disk, the upper annular disk covering the top end of the teeth of the stator core, and the lower annular disk covering the bottom end of the teeth of the stator core.

[0009] Preferably, the annular wall panel includes: a first annular wall located on the inner circumferential side of the annular disk portion, two first annular walls respectively disposed on the upper annular disk and the lower annular disk, one of the first annular walls protruding upward from the upper annular disk and the other first annular wall protruding downward from the lower annular disk; and a second annular wall located on the outer circumferential side of the annular disk portion, two second annular walls respectively disposed on the upper annular disk and the lower annular disk, one of the second annular walls protruding upward from the upper annular disk and the other second annular wall protruding downward from the lower annular disk.

[0010] Preferably, the annular disk portion includes a plurality of end insulating members, which are arranged circumferentially at intervals. The end insulating members are connected to the axial ends of two adjacent toothed insulating members. The side of the end insulating member near the stator core is formed as a horizontal plane, and the axial end face of the stator core is in contact with the horizontal plane.

[0011] Preferably, the first annular wall includes a plurality of arc-shaped plate portions, which are arranged at intervals along the circumference, and the plurality of arc-shaped plate portions are connected to the plurality of end insulating members in a one-to-one correspondence, and the winding is wound around the arc-shaped plate portions.

[0012] Preferably, the second annular wall includes: a plurality of wire guide plates, spaced apart circumferentially, the wire guide plates protruding axially from the annular disk portion, the wire guide plates being located between two adjacent end insulators, two wire guide posts being spaced apart on the wire guide plates, and the transition wire of the winding being wound around the wire guide posts; a first wire clamping post located at the end of the wire guide post away from the annular disk portion, the first wire clamping post protruding radially from the outer surface of the wire guide post; and a second wire clamping post located at the end of the wire guide post near the annular disk portion, the second wire clamping post being offset from the first wire clamping post, the second wire clamping post protruding radially from the outer surface of the wire guide post, and the transition wire being clamped between the first wire clamping post and the second wire clamping post.

[0013] Preferably, the wire guide plate has a wire-binding hole in the middle for the wire to pass through.

[0014] Preferably, the wall thickness H of the toothed insulating member is ≤ 5 mm.

[0015] According to a second aspect of the present invention, a scroll compressor is provided, wherein the scroll compressor includes a motor and an integrally formed insulating frame as described above, the integrally formed insulating frame being mounted on the stator core of the motor.

[0016] This utility model discloses an integrally molded insulating frame and scroll compressor, in which multiple toothed insulating components are disposed between two adjacent teeth of the stator core. The toothed insulating components cover the sidewalls of the teeth of the stator core to provide insulation, and extend axially through the stator core. Annular discs are disposed at both ends of the multiple toothed insulating components along the axial direction, and the stator core is sandwiched between two annular discs to provide insulation to the ends of the stator core. Annular wall plates are disposed on the annular discs. The annular wall plates protrude axially from the annular discs, allowing the motor windings to be arranged on the annular wall plates. The toothed insulating components, annular discs, and annular wall plates are integrally molded, thereby avoiding the risk of poor pressure resistance and deformation of the insulating frame. Placing the stator core into a mold and then injection molding the insulating frame ensures a stable bond between the insulating frame and the stator core, preventing loosening and peeling during use, and eliminating the cumbersome installation process. This effectively solves the problems of complex installation and easy deformation and loosening of existing stator core insulation structures.

[0017] To make the above-mentioned objectives, features and advantages of this application more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0018] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of an integrally molded insulating frame according to the present invention.

[0020] Figure 2 This is a schematic diagram of the integrally molded insulating frame of this utility model installed on the stator core.

[0021] Figure 3 This is an exploded view of the integrally formed insulating frame and stator core according to this utility model.

[0022] Figure 4This is a cross-sectional view of the integrally molded insulating frame of this utility model installed on the stator core.

[0023] Reference numerals: 1-toothed insulating component; 10-wall thickness of the toothed insulating component; 2-annular disk; 20-end insulating component; 21-upper annular disk; 22-lower annular disk; 3-annular wall plate; 31-first annular wall; 310-arc plate; 32-second annular wall; 321-wire guide plate; 322-wire guide post; 323-first wire clamping post; 324-second wire clamping post; 325-wire binding hole; 4-stator core; 40-toothed component. Detailed Implementation

[0024] The following detailed embodiments are provided to help the reader gain a comprehensive understanding of the methods, apparatus, and / or systems described herein. However, various changes, modifications, and equivalents of the methods, apparatus, and / or systems described herein will be apparent after understanding the disclosure of this application. For example, the order of operations described herein is merely illustrative and is not limited to the order set forth herein; changes that will be apparent after understanding the disclosure of this application are possible, except for operations that must occur in a specific order. Furthermore, for clarity and brevity, descriptions of features known in the art may be omitted.

[0025] The features described herein may be implemented in different forms and should not be construed as being limited to the examples described herein. Rather, the examples described herein have been provided merely to illustrate some of the many feasible ways of implementing the methods, apparatus, and / or systems described herein that will be apparent upon understanding the disclosure of this application.

[0026] Throughout the specification, when an element (such as a layer, region, or substrate) is described as being "on" another element, "connected to" another element, "bonded to" another element, "on" another element, or "covering" another element, it may be directly "on" another element, "connected to" another element, "bonded to" another element, "on" another element, or "covering" another element, or there may be one or more other elements in between. In contrast, when an element is described as being "directly on" another element, "directly connected to" another element, "directly bonded to" another element, "directly on" another element, or "directly covering" another element, there may be no other elements in between.

[0027] As used herein, the term “and / or” includes any one of the relevant items listed and any combination of any two or more items.

[0028] Although terms such as “first,” “second,” and “third” may be used herein to describe individual components, assemblies, regions, layers, or parts, these components, assemblies, regions, layers, or parts are not limited by these terms. Rather, these terms are used only to distinguish one component, assembly, region, layer, or part from another. Therefore, without departing from the teachings of the examples described herein, the first component, assembly, region, layer, or part referred to as the second component, assembly, region, layer, or part may also be referred to as the second component, assembly, region, layer, or part.

[0029] For ease of description, spatial relation terms such as “above,” “upper,” “below,” and “lower” are used herein to describe the relationship between one element and another, as shown in the accompanying drawings. Such spatial relation terms are intended to include not only the orientation depicted in the drawings but also different orientations of the device during use or operation. For example, if the device in the drawings is flipped, an element described as being “above” or “upper” relative to another element will subsequently be “below” or “lower” relative to that other element. Therefore, the term “above” includes both “above” and “below” orientations depending on the spatial orientation of the device. The device may also be positioned in other ways (e.g., rotated 90 degrees or in other orientations), and the spatial relation terms used herein will be interpreted accordingly.

[0030] The terminology used herein is for the purpose of describing various examples only and is not intended to limit the examples. Unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. The terms “comprising,” “including,” and “having” enumerate the stated features, quantities, operations, components, elements, and / or combinations thereof, but do not exclude the presence or addition of one or more other features, quantities, operations, components, elements, and / or combinations thereof.

[0031] Variations in the shapes shown in the accompanying drawings may occur due to manufacturing techniques and / or tolerances. Therefore, the examples described herein are not limited to the specific shapes shown in the accompanying drawings, but include changes in shape that may occur during manufacturing.

[0032] The features of the examples described herein can be combined in various ways that will be apparent upon understanding the disclosure of this application. Furthermore, although the examples described herein have a wide variety of constructions, other constructions are possible, as will be apparent upon understanding the disclosure of this application.

[0033] like Figures 1 to 4 As shown, according to a first aspect of the present invention, an integrally formed insulating frame is provided, the integrally formed insulating frame including a toothed insulating member 1, an annular disk portion 2, and an annular wall plate 3.

[0034] In the following description, reference will be made to Figures 1 to 4 The specific structure of the aforementioned components of the integrally molded insulating frame and the connection relationship of the aforementioned components are described in detail.

[0035] like Figures 1 to 4 As shown, in this embodiment, the number of toothed insulating members 1 can be multiple, corresponding to multiple teeth 40 of the stator core 4. The toothed insulating members 1 can be disposed between two adjacent teeth 40 of the stator core 4. The toothed insulating members 1 can cover the sidewalls of the teeth 40 of the stator core 4 (i.e., the toothed insulating members 1 are attached to the sidewalls of the teeth 40) to insulate the teeth 40 of the stator core 4. The toothed insulating members 1 can penetrate the stator core 4 axially. Two annular disk portions 2 can be disposed at both ends of the multiple toothed insulating members 1 axially. The stator core 4 can be sandwiched between the two annular disk portions 2 to insulate the ends of the stator core 4. An annular wall plate 3 can be disposed on the annular disk portion 2. The annular wall plate 3 can protrude axially from the annular disk portion 2, allowing the motor windings (not shown) to be wound and arranged on the annular wall plate 3. The toothed insulating component 1, the annular disk portion 2, and the annular wall plate 3 can be integrally molded, thereby avoiding the risk of poor pressure resistance and deformation of the integrally molded insulating skeleton. Placing the stator core 4 into a mold and then injection molding the integrally molded insulating skeleton ensures a stable bond between the stator core 4 and the integrally molded insulating skeleton, preventing loosening and peeling during use and eliminating the need for cumbersome installation procedures.

[0036] Preferred, such as Figures 1 to 3 As shown, in this embodiment, the number of toothed insulating members 1 can be equal to the number of teeth 40 of the stator core 4. That is, the mold used for injection molding the integrally formed insulating skeleton can be adaptively designed according to the specific structure of the stator core 4. When the integrally formed insulating skeleton is installed on the stator core 4, the toothed insulating members 1 are surrounded in the gap between two adjacent teeth 40, while the end face of the teeth 40 near the axis of the stator core 4 is exposed in the toothed insulating members 1.

[0037] Preferred, such as Figure 1 and Figure 4 As shown, in this embodiment, the toothed insulating member 1 is in close contact with the circumferential sidewall of the tooth 40 and the wall surface used to connect two adjacent teeth 40, so as to play an insulating role. Further, preferably, the wall thickness 10 of the toothed insulating member can be H, where H≤5mm, thereby preventing the integrally molded insulating skeleton from shrinking and collapsing during injection molding.

[0038] Preferred, such as Figures 1 to 3As shown, in this embodiment, the annular disk portion 2 may include a plurality of end insulating members 20, which may be arranged circumferentially at intervals. The end insulating members 20 cover the ends of the teeth 40 of the stator core 4, serving to insulate the ends of the teeth 40. The end insulating members 20 may be connected to the axial ends of two adjacent tooth insulating members 1. Furthermore, the side of the end insulating member 20 near the stator core 4 may be formed as a horizontal surface, allowing the axial end face of the stator core 4 to conform to the horizontal surface.

[0039] Preferred, such as Figures 1 to 3 As shown, in an embodiment, the annular disk portion 2 may include an upper annular disk 21 and a lower annular disk 22 (to...). Figure 2 The upward direction shown is upward, with Figure 2 (The downward direction shown is "down"), the upper annular disk 21 and the lower annular disk 22 are symmetrically arranged. The upper annular disk 21 can cover the top axial end of the teeth 40 of the stator core 4, and the lower annular disk 22 can cover the bottom axial end of the teeth 40 of the stator core 4.

[0040] Furthermore, preferably, such as Figures 1 to 3 As shown, in this embodiment, the annular wall panel 3 may include a first annular wall 31 and a second annular wall 32. The first annular wall 31 may be located on the inner circumference of the annular disk portion 2. The two first annular walls 31 may be respectively disposed on the upper annular disk 21 and the lower annular disk 22. One first annular wall 31 protrudes upward from the upper annular disk 21, and the other first annular wall 31 protrudes downward from the lower annular disk 22, facilitating winding. The second annular wall 32 may be located on the outer circumference of the annular disk portion 2. The two second annular walls 32 may be respectively disposed on the upper annular disk 21 and the lower annular disk 22. One second annular wall 32 protrudes upward from the upper annular disk 21, and the other second annular wall 32 protrudes downward from the lower annular disk 22, facilitating winding.

[0041] Specifically, such as Figures 1 to 3 As shown, in this embodiment, the first annular wall 31 may include a plurality of arc-shaped plate portions 310. The width of the arc-shaped plate portions 310 gradually increases along the direction close to the stator core 4, and the wall surface of the arc-shaped plate portions 310 may be formed as an arc surface. The plurality of arc-shaped plate portions 310 may be arranged circumferentially at intervals, and the plurality of arc-shaped plate portions 310 are connected to a plurality of end insulating members 20 in a one-to-one correspondence. The plurality of windings may be wound around the plurality of arc-shaped plate portions 310 respectively, such that the plurality of windings are arranged at intervals from each other.

[0042] Further optimized, such as Figures 1 to 3As shown, in this embodiment, the second annular wall 32 may include a plurality of wire guide plates 321, a first wire-holding post 323, and a second wire-holding post 324. The plurality of wire guide plates 321 may be arranged circumferentially at intervals, and each wire guide plate 321 may protrude axially from the annular disk portion 2. The wire guide plates 321 are located on the outer periphery of the annular disk portion 2 and are disposed between two adjacent end insulators 20. Two wire guide posts 322 may be arranged at intervals on each wire guide plate 321, and the transition wire for winding may be wound around the wire guide post 322. The first wire-holding post 323 may be located at the end of one of the wire guide posts 322 away from the annular disk portion 2, and the first wire-holding post 323 protrudes radially from the outer surface of the wire guide post 322. The second wire-holding post 324 may be located at the end of the other wire guide post 322 near the annular disk portion 2, such that the second wire-holding post 324 is staggered from the first wire-holding post 323. The second wire-holding post 324 protrudes radially from the outer surface of the wire guide post 322. During use, the transition line can be wound around the two wire guide posts 322 of the wire guide plate 321 in the circumferential direction, and the transition line is locked between the first wire guide post 323 and the second wire guide post 324 to prevent the transition line from shifting or falling off.

[0043] Preferred, such as Figures 1 to 3 As shown in the embodiment, the center of the wire guide plate 321 may also have a wire-binding hole 325 for the wire to pass through. The operator can pass the wire through the wire-binding hole 325 to secure the transition wire and the motor's lead wire. Additionally, the second annular wall 32 also serves as an insulating barrier, separating the energized winding from the motor's metal casing or other conductive components at different potentials to prevent electrical conduction.

[0044] Furthermore, according to a second aspect of the present invention, a scroll compressor is provided, the scroll compressor comprising a motor and an integrally formed insulating frame as described above, the integrally formed insulating frame being mounted on the stator core 4 of the motor.

[0045] During use, the mold for the integrally formed insulating skeleton can be designed according to the stator core 4, meaning the mold can be adaptively changed according to the shape and stacking height of the stator core 4. First, the stator core 4 is placed in the mold, then the raw material for the integrally formed insulating skeleton is heated and injected into the mold through an injection molding machine. After the raw material solidifies, it is demolded. At this point, the integrally formed insulating skeleton can achieve a stable bond with the stator core 4 without loosening or peeling, and it has strong pressure resistance. The integrally formed insulating skeleton has high structural strength and rigidity, eliminating seams, connection points, or potential weak points present in traditional assembly structures. It can better resist vibration, impact, electromagnetic force during motor operation, and stress during assembly, reducing the risk of deformation, cracking, or displacement. Furthermore, the integrally formed insulating skeleton avoids burrs, gaps, or insulation gaps caused by improper assembly during the assembly process, avoids potential creepage distance shortening points, significantly improves dielectric strength and pressure resistance, and greatly enhances the electrical safety and long-term operational reliability of the motor.

[0046] Finally, it should be noted that the above-described embodiments are merely specific implementations of this application, used to illustrate the technical solutions of this application, and not to limit them. The scope of protection of this application is not limited thereto. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that any person skilled in the art can still modify or easily conceive of changes to the technical solutions described in the foregoing embodiments, or make equivalent substitutions for some of the technical features, within the scope of the technology disclosed in this application. Such modifications, changes, or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be covered within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. An integrally molded insulation framework mounted to a stator core of an electric machine, characterized by, The integrally molded insulating frame includes: Multiple toothed insulating elements are disposed between two adjacent teeth of the stator core, the toothed insulating elements cover the sidewalls of the teeth of the stator core, and the toothed insulating elements penetrate the stator core axially; An annular disk portion is disposed at both ends axially of the plurality of toothed insulating members, and the stator core is clamped between two of the annular disk portions; and An annular wall panel is disposed on the annular disk portion, the annular wall panel protrudes axially from the annular disk portion, and the windings of the motor are arranged on the annular wall panel; The toothed insulating component, the annular disk portion, and the annular wall plate are integrally formed.

2. The integrally formed insulating skeleton according to claim 1, wherein The number of the plurality of toothed insulators is equal to the number of teeth of the stator core. The toothed insulators are arranged in the gap between two adjacent teeth, and the end face of the teeth near the axis of the stator core is exposed in the toothed insulators.

3. The integrally formed insulating skeleton according to claim 1, wherein The annular disk portion includes an upper annular disk and a lower annular disk. The upper annular disk covers the top end of the teeth of the stator core, and the lower annular disk covers the bottom end of the teeth of the stator core.

4. The integrally formed insulating skeleton according to claim 3, wherein The annular wall panel includes: A first annular wall is located on the inner circumference of the annular disk portion. Two first annular walls are respectively disposed on the upper annular disk and the lower annular disk, one of the first annular walls protruding upward from the upper annular disk and the other first annular wall protruding downward from the lower annular disk; and The second annular wall is located on the outer periphery of the annular disk portion. Two second annular walls are respectively disposed on the upper annular disk and the lower annular disk. One of the second annular walls protrudes upward from the upper annular disk, and the other second annular wall protrudes downward from the lower annular disk.

5. The integrally molded insulating frame according to claim 4, characterized in that, The annular disk includes a plurality of end insulating members, which are arranged circumferentially at intervals. The end insulating members are connected to the axial ends of two adjacent toothed insulating members. The side of the end insulating member near the stator core is formed as a horizontal plane, and the axial end face of the stator core is in contact with the horizontal plane.

6. The integrally formed insulating skeleton according to claim 5, wherein The first annular wall includes a plurality of arc-shaped plate portions, which are arranged at intervals along the circumference. The plurality of arc-shaped plate portions are connected to the plurality of end insulating members in a one-to-one correspondence, and the winding is wound around the arc-shaped plate portions.

7. The integrally formed insulating skeleton of claim 5, wherein The second annular wall includes: Multiple wire guide plates are arranged at intervals along the circumference. The wire guide plates protrude axially from the annular disk portion. The wire guide plates are located between two adjacent end insulating members. Two wire guide posts are arranged at intervals on the wire guide plates. The transition wire of the winding is wound around the wire guide posts. A first wire-locking post is located at the end of the wire-passing post away from the annular disk portion, and the first wire-locking post protrudes radially from the outer surface of the wire-passing post; and The second wire-clamping post is located at the end of the wire-passing post near the annular disc. The second wire-clamping post is offset from the first wire-clamping post and protrudes radially from the outer surface of the wire-passing post. The transition line is clamped between the first wire-clamping post and the second wire-clamping post.

8. The integrally formed insulating skeleton according to claim 7, wherein The wire guide plate has a binding hole in the middle for the binding wire to pass through.

9. The integrally formed insulating skeleton of claim 2, wherein, The wall thickness H of the tooth insulation piece is ≤ 5 mm.

10. A scroll compressor characterized by, The scroll compressor comprises a motor and the integrally formed insulation framework of any one of claims 1 to 9, which is mounted to a stator core of the motor.

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