An outer rotor motor with a stator core integrally injection molded insulation package

Abstract

The utility model belongs to motor technical field discloses a kind of outer rotor motor of stator core integral injection molding insulation packaging, including the stator core with stator yoke, multiple stator teeth and multiple coil winding;Stator core is connected with one first connecting column and at least one second connecting column, first connecting column and second connecting column;The public end of each coil winding is electrically connected with the one end of first connecting column;The starting end of coil winding of corresponding phase is electrically connected with the one end of second connecting column;Stator core is equipped with injection molding part, injection molding part is formed by insulating material injection molding, injection molding part covers stator core, first connecting column and the one end of second connecting column coil winding;The other end of second connecting column is extended to the outside of injection molding part to the same side along stator yoke axis direction;Effectively solve the problem that the existing technology has redundant motor structure to meet the requirement of creepage distance, insufficient insulation reliability, and cannot take into account high-pressure safety and compact design.

Description

Technical Field

[0001] This utility model belongs to the field of motor technology, specifically relating to an external rotor motor with an integrally injection-molded and insulated stator core. Background Technology

[0002] In the design of high-voltage external rotor motors, the insulation safety between the drive board and the stator coils is a key technical challenge. The drive board, as the core of motor control, integrates high-voltage components such as MOSFETs and capacitors, and needs to drive the stator coils via electrical connections. Traditional designs use wire connections. To meet the 4mm creepage distance requirement specified in GB 7251.1-2023, the following measures must be taken: firstly, an excessively large safety clearance must be reserved between the wires and metal components; secondly, additional structures such as insulating sleeves and isolation brackets must be added. This design method directly leads to a significant increase in the axial dimension of the motor and multiple structural redundancies. Therefore, existing technologies suffer from structural redundancy and insufficient insulation reliability due to the need to meet creepage distance requirements, and cannot simultaneously achieve high-voltage safety and a compact design. Utility Model Content

[0003] To address the shortcomings of existing technologies, the purpose of this utility model is to provide an external rotor motor with an integral injection-molded and insulated stator core, which solves the problems in existing technologies such as redundant motor structure, insufficient insulation reliability, and inability to balance high-voltage safety and compact design in order to meet creepage distance requirements.

[0004] The objective of this utility model can be achieved through the following technical solutions:

[0005] An external rotor motor with integral injection molding and insulation encapsulation of stator core includes a stator core having a stator yoke, multiple stator teeth, and multiple coil windings;

[0006] The stator core is connected to a first connecting post and at least one second connecting post, the first connecting post and the second connecting post;

[0007] One end of the first connecting post is electrically connected to the common terminal of each coil winding;

[0008] One end of each of the second connecting posts is electrically connected to the starting end of the coil winding of the corresponding phase;

[0009] The stator core is provided with an injection molded part, which is injection molded from insulating material. The injection molded part covers the stator core, the first connecting post, and the second connecting post, and connects one end of the coil winding.

[0010] The other end of the second connecting column extends to the same side along the direction of the stator yoke axis to the outside of the injection molded part.

[0011] The insulating material used in the processing of injection molded parts contains glass fibers.

[0012] The stator yoke is equipped with a sleeve placed on the same axis. The stator yoke is sleeved on the outer peripheral wall of the sleeve, and the sleeve is connected to the injection molded part.

[0013] The injection molded part has an outer shell, which is a cylindrical shell with one end open. The outer shell and the sleeve are placed on the same axis. A magnetic ring is fixed on the inner peripheral wall of the outer shell and placed on the same axis. The stator core and the sleeve are placed inside the magnetic ring.

[0014] A rotating shaft is rotatably connected inside the sleeve, and the rotating shaft is fixedly connected to the outer shell away from the opening end.

[0015] The end of the stator teeth away from the central axis of the stator yoke is rounded, and the rounded surface is exposed on the outside of the injection molded part.

[0016] The outer peripheral wall of the sleeve is provided with at least one protrusion, which is placed coaxially with the sleeve. The inner side wall of the stator yoke is provided with a groove that matches the protrusion.

[0017] At least one bearing is fitted onto the rotating shaft, and the bearing is mounted on the inner wall of the sleeve.

[0018] The number of second connecting posts is three.

[0019] The injection molded part has a groove near the exposed end of the second connecting post, and a drive plate is connected in the groove. All the second connecting posts are connected to the drive plate.

[0020] Multiple connecting sleeves are embedded in the injection molded part for fixed connection with the motor back cover or mounting bracket by fasteners;

[0021] The connecting sleeve and the groove are located at the same end of the injection molded part, and the connecting sleeve is located outside the groove.

[0022] Insulating materials include BMC materials.

[0023] The beneficial effects of this utility model are:

[0024] This application utilizes an integral injection molding process to encapsulate the stator core and coil windings with insulating material.

[0025] The injection-molded part completely encapsulates the stator core and its coil windings, forming a continuous and uniform insulation layer between the energized coil windings and external components, ensuring that the creepage distance requirements for high-voltage insulation are met. Simultaneously, the injection-molded part provides structural support for the stator core, enhancing overall mechanical strength. The second connecting post adopts an axially extended design, with its terminals directly exposed on the outside of the injection-molded body, ensuring reliable electrical connections while avoiding the space waste associated with traditional wire connection methods. This integrated injection-molded encapsulation structure significantly optimizes the overall size of the motor while ensuring insulation performance, effectively solving the problems of redundant motor structure, insufficient insulation reliability, and inability to balance high-voltage safety and compact design in existing technologies that prioritize creepage distance requirements. Attached Figure Description

[0026] 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, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 This is a schematic diagram showing the state of the external rotor motor with the impeller installed according to this utility model;

[0028] Figure 2 This is a schematic diagram of the overall structure of the external rotor motor of this utility model;

[0029] Figure 3 This is a schematic diagram of a portion of the magnetic ring structure of this utility model;

[0030] Figure 4 This is a partial structural diagram of the drive board of this utility model;

[0031] Figure 5 This is a schematic diagram of the sleeve portion of this utility model;

[0032] Figure 6 This is a partial structural diagram of the first connecting column of this utility model;

[0033] Figure 7 This is a schematic diagram of the structure of the protruding strip part of this utility model. Detailed Implementation

[0034] 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 skilled in the art without creative effort are within the protection scope of the present utility model.

[0035] like Figures 1 to 7 As shown, an external rotor motor with integral injection molding and insulation encapsulation of stator core includes a stator core 100 having a stator yoke 101, multiple stator teeth 102 and multiple coil windings;

[0036] The stator core 100 is connected to a first connecting post 200 and at least one second connecting post 300, the first connecting post 200 and the second connecting post 300;

[0037] One end of the first connecting post 200 is electrically connected to the common terminal of each coil winding;

[0038] One end of the second connecting post 300 is electrically connected to the starting end of the coil winding of the corresponding phase;

[0039] The stator core 100 is provided with an injection molded part 400, which is injection molded from insulating material. The injection molded part 400 covers the stator core 100, the first connecting post 200 and the second connecting post 300 and connects one end of the coil winding.

[0040] The other end of the second connecting column 300 extends to the same side along the axis of the stator yoke 101 to the outside of the injection molded part 400.

[0041] It should be noted that during the assembly and production of the external rotor motor of this application, the stator core 100 is first placed in the mold, and then the molten insulating material is poured into the mold. The insulating material immerses the stator core 100, and after cooling and solidification, it forms an injection molded part 400 covering the stator core 100.

[0042] It should be noted that the coil winding can be connected to the first connecting post 200 and / or the second connecting post 300 by welding.

[0043] This application utilizes an injection-molded part 400 made of insulating material to encapsulate the stator core 100. After solidification, the injection-molded part 400 forms a stable structure, providing stable support for the stator core 100. Simultaneously, the injection-molded part 400, also made of insulating material, encapsulates the coil windings, creating a continuous insulating layer between the coil windings and external components. This ensures a safe creepage distance between the coil windings and external components, eliminating the need for additional insulation structures between the coil windings and external components. Furthermore, by extending one end of the first connecting post 200 and the second connecting post 300 to the outside of the injection-molded part 400, the electrical connection function is directly achieved. Compared to traditional wire connection methods, this eliminates the need for additional insulating components such as insulating sleeves and isolation brackets, simplifying the connection structure. This integrated injection-molded encapsulation structure not only simplifies the manufacturing process but also significantly improves the overall insulation reliability of the product by eliminating weak points in traditional wire connections. It achieves a compact design of the motor structure while ensuring high-voltage safety, effectively resolving the contradiction between the insulation requirements and miniaturization of high-voltage motors.

[0044] It should be noted that the stator teeth 102 are all fixed on the outer wall of the stator yoke 101, and the multiple stator teeth 102 are evenly distributed in a ring; the number of coil windings is equal to that of stator teeth 102 and they correspond one-to-one, and the coil windings are all set on the corresponding stator teeth 102.

[0045] Preferably, the surface of the stator tooth 102 is provided with an insulating frame, which is used to isolate the stator tooth 102 from the coil winding to prevent the two from directly contacting each other and causing a short circuit; the insulating frame can be made of epoxy resin or plastic with an insulation class of B or above.

[0046] Preferably, both the first connecting post 200 and the second connecting post 300 can be made of pins or the like.

[0047] Glass fiber is incorporated into the insulating material of the injection molded part 400; the glass fiber enhances the structural strength of the injection molded part 400 and improves its heat dissipation performance.

[0048] Preferably, the glass fiber length is 5 mm to 30 mm.

[0049] The stator yoke 101 is provided with a sleeve 500 placed on the same axis. The stator yoke 101 is sleeved on the outer peripheral wall of the sleeve 500, and the sleeve 500 is connected to the injection molded part 400.

[0050] The injection molded part 400 is provided with an outer shell 600. The outer shell 600 is a cylindrical shell with one end open. The outer shell 600 and the sleeve 500 are placed on the same axis. A magnetic ring 601 placed on the same axis is fixed on the inner peripheral wall of the outer shell 600. The stator core 100 and the sleeve 500 are both placed inside the magnetic ring 601.

[0051] A rotating shaft 700 is rotatably connected inside the sleeve 500 and placed on the same axis. The rotating shaft 700 is fixedly connected to the outer shell 600 away from the opening end.

[0052] After the coil winding is energized, the magnetic ring 601 drives the outer shell 600 and the rotating shaft 700 to rotate.

[0053] Preferably, the sleeve 500 has a lug on its outer side wall, so that the sleeve 500 can be connected to the stator core 100 first, and then the injection molded part 400 can be injection molded.

[0054] Preferably, the lug and the injection molded part 400 are detachably connected by bolts;

[0055] Preferably, a wind turbine 502, which is placed coaxially, is fixedly connected to the rotating shaft 700 or the housing 600.

[0056] The end of the stator tooth 102 away from the central axis of the stator yoke 101 is a rounded surface, and the rounded surface is exposed on the outside of the injection molded part 400.

[0057] The exposed arc surface forms a precise fit with the magnetic ring 601, optimizing the magnetic field distribution and improving the motor output performance; at the same time, the exposed arc surface of the stator teeth 102 enhances the heat dissipation effect and effectively reduces the operating temperature.

[0058] The outer peripheral wall of the sleeve 500 is provided with at least one protrusion 501, the protrusion 501 is placed in the same direction as the sleeve 500, and the inner side wall of the stator yoke 101 is provided with a groove 103 that is adapted to the protrusion 501.

[0059] The axial insertion design of the protrusion 501 and the slot 103 enables a quick connection between the stator core 100 and the sleeve 500, while avoiding relative rotation between the sleeve 500 and the stator yoke 101 around the central axis, further improving the stability of the sleeve 500 connection.

[0060] At least one bearing 701 is sleeved on the rotating shaft 700, and the bearing 701 is installed on the inner wall of the sleeve 500;

[0061] Preferably, a corresponding bearing chamber is provided on the inner peripheral wall of the sleeve 500, and the rolling bearing 701 is installed in the bearing chamber, with the outer ring of the bearing 701 fitting against the peripheral wall of the bearing chamber.

[0062] Preferably, the rotating shaft 700 and the inner ring of the bearing 701 are fixed by an interference fit.

[0063] Preferably, the number of bearings 701 inside the sleeve 500 is two;

[0064] Preferably, the bearing 701 has one or two compression pads at its end. The compression pads are in the form of three or four peaks and are made of stainless steel or spring steel to avoid or reduce the problem of bearing 701 being damaged due to bumps during the transportation of the motor.

[0065] By setting bearing 701, the stability of the connection between shaft 700 and sleeve 500 is improved, and the shaft 700 is prevented from shaking during rotation.

[0066] There are three second connecting posts 300; the three second connecting posts 300 correspond to the U, V and W three-phase leads of the three-phase motor respectively.

[0067] The injection molded part 400 has a groove 401 near the exposed end of the second connecting post 300. The drive plate 800 is connected in the groove 401, and the second connecting posts 300 are all connected to the drive plate 800. The exposed ends of the three second connecting posts 300 pass through the corresponding through holes on the drive plate 800, and are electrically connected by welding or pressing. The depth design of the groove 401 ensures that the second connecting posts 300 and the drive plate 800 are completely enclosed.

[0068] It should be noted that the driver board 800 is equipped with Hall effect devices or Hall effect integrated devices with inductive magnetic poles.

[0069] Multiple connecting sleeves 402 are embedded on the injection molded part 400 for fixed connection with the motor rear cover 900 or mounting bracket by fasteners.

[0070] The connecting sleeve 402 and the groove 401 are located at the same end of the injection molded part 400, and the connecting sleeve 402 is located outside the groove 401;

[0071] Preferably, the connecting sleeve 402 is made of metal and is integrally injection molded with the injection molded part 400;

[0072] Preferably, the connecting sleeve 402 has a threaded hole; the fastener is a bolt or screw, etc.

[0073] Preferably, there are multiple connecting sleeves 402, some of which are used to connect the motor rear cover 900, and the remaining connecting sleeves 402 are used to connect the mounting bracket.

[0074] Preferably, the drive plate 800 is located between the motor rear cover 900 and the groove 401, and is detachably connected to the motor rear cover 900 by bolts or the like.

[0075] Insulation materials include BMC material; BMC material has excellent insulation properties, and its excellent mechanical properties provide solid support for the stator assembly, enhancing the overall structural strength; the one-piece molding characteristic not only simplifies the production process, but also eliminates the joint hazards of traditional insulation structures, significantly improving product reliability.

[0076] Meanwhile, the high temperature resistance and arc resistance of BMC material ensure the stable operation of the motor under long-term high voltage operation, achieving an optimized balance between insulation performance and structural strength;

[0077] The lower density of BMC material compared to metals results in a lighter weight for the same volume. This lightweight design not only facilitates installation and maintenance but also reduces inertial losses during motor operation, making it particularly suitable for weight-sensitive applications.

[0078] In the description of this specification, references to terms such as "an embodiment," "example," "specific example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0079] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claims of this utility model.

Claims

1. An external rotor motor with integral injection-molded insulated stator core, comprising a stator core (100) having a stator yoke (101), multiple stator teeth (102), and multiple coil windings, characterized in that, The stator core (100) is connected to a first connecting post (200) and at least one second connecting post (300), the first connecting post (200) and the second connecting post (300); One end of the first connecting post (200) is electrically connected to the common terminal of each coil winding; One end of each of the second connecting posts (300) is electrically connected to the starting end of the coil winding of the corresponding phase; The stator core (100) is provided with an injection molded part (400), which is injection molded from insulating material. The injection molded part (400) covers the stator core (100), the first connecting post (200) and the second connecting post (300) connecting one end of the coil winding. The other end of the second connecting post (300) extends to the same side along the axis of the stator yoke (101) to the outside of the injection molded part (400).

2. The external rotor motor with integral injection-molded insulated stator core as described in claim 1, characterized in that, The insulating material of the injection molded part (400) is doped with glass fiber.

3. The external rotor motor with integral injection-molded insulated stator core as described in claim 1 or 2, characterized in that, The stator yoke (101) is provided with a sleeve (500) placed on the same axis. The stator yoke (101) is sleeved on the outer peripheral wall of the sleeve (500). The sleeve (500) is connected to the injection molded part (400). The injection molded part (400) has an outer shell (600) on the outside. The outer shell (600) is a cylindrical shell with one end open. The outer shell (600) and the sleeve (500) are placed on the same axis. A magnetic ring (601) placed on the same axis is fixed on the inner peripheral wall of the outer shell (600). The stator core (100) and the sleeve 5 (00) are both placed inside the magnetic ring (601). A rotating shaft (700) is rotatably connected inside the sleeve (500) and is placed on the same axis. The rotating shaft (700) is fixedly connected to the outer shell (600) away from the opening end.

4. The external rotor motor with integral injection-molded insulated stator core as described in claim 3, characterized in that, The end of the stator tooth (102) away from the central axis of the stator yoke (101) is a rounded surface, and the rounded surface is exposed on the outside of the injection molded part (400).

5. The external rotor motor with integral injection-molded insulated stator core as described in claim 4, characterized in that, The outer peripheral wall of the sleeve (500) is provided with at least one protrusion (501), the protrusion (501) and the sleeve (500) are placed in the same direction, and the inner side wall of the stator yoke (101) is provided with a groove (103) that matches the protrusion (501).

6. The external rotor motor with integral injection-molded insulated stator core as described in claim 5, characterized in that, At least one bearing (701) is sleeved on the rotating shaft (700), and the bearing (701) is installed on the inner wall of the sleeve (500).

7. The external rotor motor with integral injection-molded insulated stator core as described in claim 1, characterized in that, The number of second connecting posts (300) is three.

8. The external rotor motor with integral injection-molded insulated stator core as described in claim 7, characterized in that, The injection molded part (400) has a groove (401) near the exposed end of the second connecting post (300). A drive plate (800) is connected in the groove (401), and the second connecting post (300) is connected to the drive plate (800).

9. The external rotor motor with integral injection-molded insulated stator core as described in claim 8, characterized in that, Multiple connecting sleeves (402) are embedded on the injection molded part (400) for fixed connection with the motor rear cover (900) or mounting bracket by fasteners; The connecting sleeve (402) and the groove (401) are located at the same end of the injection molded part (400), and the connecting sleeve (402) is located outside the groove (401).

10. The external rotor motor with integral injection-molded insulated stator core as described in claim 1, characterized in that, Insulating materials include BMC materials.

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