Flat wire motor, powertrain, and vehicle

Abstract

The embodiment of the application provides a flat wire motor, a power assembly and a vehicle, relates to the technical field of the flat wire motor, and is used for improving the heat dissipation performance of a motor stator. The flat wire motor comprises a motor stator and a motor rotor, the motor stator comprises a plurality of stator slots, the plurality of stator slots are arranged at intervals along the circumference of the motor stator, each stator slot is used for accommodating a plurality of flat wires, and the plurality of flat wires in each stator slot are sequentially arranged in layers along the radial direction of the motor stator, wherein an insulating paper is arranged in each stator slot, and the outer periphery of the plurality of flat wires in the stator slot is surrounded by the single-layer insulating paper. The single-layer insulating paper eliminates the superimposed part or the overlapping part, the occupied space of the insulating paper in the stator slot is reduced, the occupied space of the flat wire in the stator slot is improved, and the heat dissipation performance of the motor stator is improved.

Description

Technical Field

[0001] This application relates to the field of flat wire motor technology, and more particularly to a flat wire motor, powertrain, and vehicle. Background Technology

[0002] Flat-wire motors are a type of motor that uses flat rectangular conductors as stator windings. Compared to traditional motors that use round conductors, flat-wire motors have higher copper fill factor, higher power density, higher efficiency, and better heat dissipation performance, and are widely used in new energy vehicles, industrial equipment, and other fields.

[0003] The copper fill factor of the flat wires in the stator slots of a flat wire motor is a crucial parameter in motor design, directly impacting the motor's efficiency and heat dissipation performance. Increasing the copper fill factor means increasing the density of the flat wires within the stator slots. This results in higher current and magnetic flux densities, thus improving motor efficiency and power density. Furthermore, it increases the contact area between the flat wires and thermally conductive materials such as the impregnating varnish, enhancing the heat transfer efficiency of the flat wires within the stator slots and improving the overall heat dissipation performance of the motor stator. Utility Model Content

[0004] This application provides a flat wire motor, powertrain, and vehicle to increase the space occupied by the flat wire in the stator slot and improve the heat dissipation performance of the motor stator.

[0005] To achieve the above objectives, this application adopts the following technical solution:

[0006] In a first aspect, this application provides a flat wire motor, which includes a motor stator and a motor rotor. The motor stator includes a plurality of stator slots, which are spaced apart circumferentially along the motor stator. Each stator slot is used to accommodate a plurality of flat wires. The plurality of flat wires in each stator slot are arranged in layers sequentially along the radial direction of the motor stator. Insulating paper is provided in each stator slot, and a single layer of insulating paper surrounds the outer periphery of the plurality of flat wires in the stator slot.

[0007] In the flat wire motor disclosed in this application, the insulating paper serves two purposes: firstly, it isolates the electrical connection between the multiple flat wires and the stator core, preventing direct contact between the flat wires and the stator core that could lead to short circuits or leakage, thus ensuring the safety and performance of the flat wire motor; secondly, it fills the gaps between the stator slots and the multiple flat wires, ensuring the geometric shape of the flat wires within the stator slots and preventing displacement or deformation of the flat wires due to vibration or thermal expansion.

[0008] Single-layer insulation paper should be understood as insulation paper without overlap or splicing. Compared to solutions with overlapping or spliced ​​insulation paper, single-layer insulation paper eliminates the overlapping or splicing portions, reducing the space occupied by the insulation paper in the stator slots and increasing the space occupied by the flat wire in the stator slots. The increased space occupied by the flat wire in the stator slots results in higher current and magnetic flux densities in the flat wire motor, thereby improving the motor's efficiency and power density. Furthermore, it increases the contact area between the flat wire and the heat-conducting materials such as the impregnating varnish in the stator slots, improving the heat conduction efficiency of the flat wire within the stator slots and thus enhancing the heat dissipation performance of the motor stator.

[0009] In some embodiments, the flat wire is a copper flat wire, and the increased space occupied by the flat wire in the stator slot should be understood as an increase in the copper fill factor. By using a single layer of insulating paper, the efficiency and power density of the flat wire motor are improved, while the thermal conductivity of the flat wire in the stator slot is also increased, thereby improving the heat dissipation performance of the motor stator.

[0010] In one embodiment, the surface of the outer peripheral insulating paper along the multiple flat wires in the stator slot is flat and of uniform thickness.

[0011] The smooth surface of the insulating paper reduces the friction between the insulating paper and the flat wire. When the flat wire is embedded into the stator slot, the reduced friction allows for a higher embedding speed and improves production efficiency.

[0012] The uniform thickness of the insulating paper ensures that it can withstand voltage evenly in an electric field, avoiding localized electric field concentration and reducing the risk of the insulating paper being broken down. On the other hand, it also prevents the flat wire from being too tight or too loose in some areas during the embedding process, reducing the risk of flat wire deformation.

[0013] In one embodiment, the insulating paper is an integrally molded structural component.

[0014] On the one hand, it eliminates the overlapping or overlapping parts of existing insulation paper, thereby reducing the space occupied by the insulation paper in the stator slot and increasing the space occupied by the flat wire in the stator slot. On the other hand, it facilitates the insertion of the insulation paper into the stator slot, reducing assembly steps and improving assembly efficiency.

[0015] In one embodiment, the stator slot has a slot opening and a slot wedge at the end facing the motor rotor. Multiple flat wires within the stator slot, including a first flat wire, are arranged in the slot. The distance between the first flat wire and the slot wedge is less than the distance between other flat wires within the stator slot and the slot wedge. The slot wedge is used to seal the slot opening and to support the first flat wire. A gap exists between the slot wedge and the first flat wire, serving as a channel for coolant flow.

[0016] Since multiple flat wires in each stator slot are arranged in layers along the radial direction of the motor stator, the distance between the first flat wire and the slot wedge is smaller than the distance between the other flat wires in the stator slot and the slot wedge. Therefore, the first flat wire is the flat wire closest to the slot opening among the multiple flat wires.

[0017] The slot wedge provides mechanical support for the first flat wire, bearing the electromagnetic force and mechanical stress generated during operation, preventing deformation or damage. Furthermore, the slot wedge secures multiple flat wires within the stator slots, preventing displacement due to centrifugal or electromagnetic forces during flat wire motor operation, thus reducing the risk of vibration and noise caused by wire displacement. The slot wedge also fills the gap between the flat wire and the stator slots, reducing air gaps and minimizing the risk of partial discharge.

[0018] Because the flat wire at the slot opening generates significant heat, the gap between the slot wedge and the first flat wire is used as a channel for coolant flow. As the coolant flows within this channel, it comes into direct contact with the flat wire, carrying away its heat and reducing the temperature and losses at the slot opening, thereby improving the heat dissipation efficiency of the motor stator.

[0019] In one embodiment, at least one support portion is provided at one end of the slot wedge facing the first flat wire. The support portion is used to support the first flat wire, and the dimension of the support portion along the circumferential direction of the motor stator is smaller than the dimension of the first flat wire along the circumferential direction of the motor stator.

[0020] Since the dimension of the support part along the circumference of the motor stator is smaller than the dimension of the first flat wire along the circumference of the motor stator, it is ensured that a gap is formed between the other parts of the slot wedge (excluding the support part) and the first flat wire, so that a channel for coolant flow can be formed through the gap between the other parts of the slot wedge (excluding the support part) and the first flat wire.

[0021] In some embodiments, a support portion is provided at one end of the slot wedge facing the first flat wire. The channel is located between the support portion and the circumferential wall of the stator slot.

[0022] In other embodiments, the end of the slot wedge facing the first flat wire is provided with multiple support portions. Two adjacent support portions serve as two circumferential sidewalls of a channel.

[0023] In one embodiment, the support portion includes one support portion for supporting the middle position of the first flat wire along the circumferential direction of the motor stator, and the gap between at least one end of the support portion along the circumferential direction of the motor stator and the groove wall of the stator slot serves as a channel.

[0024] The support section is used to support the first flat wire at the middle position along the circumference of the motor stator, so that the support point is located at the middle position of the first flat wire along the circumference of the motor stator. Compared with the support section supporting other positions of the first flat wire, the support section with the same cross-sectional size supporting the middle position has a higher load-bearing capacity, the first flat wire is subjected to more uniform force, the local stress concentration of the first flat wire is reduced, and the stability is higher.

[0025] Under the same supporting force, the cross-sectional dimension of the support portion located in the middle position is smaller than that of the support portion located in other positions. Therefore, under the same supporting force, placing the support portion in the middle position reduces the cross-sectional dimension of the support portion, thereby reducing the space occupied and the amount of material used, resulting in lower cost and smaller space occupation.

[0026] In some embodiments, the gap between one end of the circumferential support portion of the motor stator and the wall of the stator slot is used as a channel to increase the heat dissipation efficiency of the flat wire at the slot opening, which is applicable to flat wire motors where the heat generation of the flat wire at the slot opening is relatively small.

[0027] In other embodiments, the gaps between the two ends of the circumferential support portion of the motor stator and the slot wall of the stator slot are respectively used as channels. By setting two channels, the contact area between the coolant and the flat wire is increased, thereby further improving the heat dissipation efficiency of the flat wire at the slot opening, and thus further improving the heat dissipation efficiency of the motor stator. This is applicable to flat wire motor scenarios where the flat wire at the slot opening generates a large amount of heat.

[0028] In one embodiment, the dimension of the channel along the circumference of the motor stator is larger than the dimension of the support portion along the circumference of the motor stator.

[0029] In some embodiments, the channel includes one whose dimension along the circumference of the motor stator is larger than the dimension of the support portion along the circumference of the motor stator.

[0030] In other embodiments, the channel comprises two channels, the sum of which is greater than the dimension of the support portion along the circumference of the motor stator.

[0031] By ensuring that the dimension of the channel along the circumference of the motor stator (or the sum of the dimensions of the two channels along the circumference of the motor stator) is greater than the dimension of the support portion along the circumference of the motor stator, the contact area between the coolant in the channel and the first flat wire is greater than the contact area between the support portion and the first flat wire, thereby improving the heat dissipation efficiency of the coolant on the first flat wire.

[0032] In one embodiment, the support portion includes two parts, which are respectively used to support the two ends of the first flat wire along the circumferential direction of the motor stator, and the gap between the two support portions serves as a channel.

[0033] The first flat wire is supported at both ends along the circumference of the motor stator by two support parts, which provide support force to the first flat wire and ensure its stability. Since multiple flat wires in each stator slot are arranged in layers along the radial direction of the motor stator, supporting the first flat wire by the two support parts also supports the other flat wires in the stator slot.

[0034] In this embodiment, the gap between the two support portions serves as a channel, allowing the middle position of the first flat wire to contact the coolant. Since the middle position of the first flat wire has low heat dissipation efficiency, the coolant preferentially cools the middle position of the first flat wire to achieve rapid cooling.

[0035] In one embodiment, the dimension of the channel along the circumference of the motor stator is smaller than the dimension of the first flat wire along the circumference of the motor stator.

[0036] Since each support section supports the first flat wire, the dimension of the channel along the circumference of the motor stator is smaller than the dimension of the first flat wire along the circumference of the motor stator, so as to ensure the stable support of the support section for the first flat wire.

[0037] In one embodiment, the slot wedge includes a blocking portion connected to a supporting portion. The blocking portion is used to block the slot opening, and the end of the blocking portion facing the first flat line is at least flush with the end of the slot opening facing the first flat line.

[0038] In some embodiments, the end of the blocking portion facing the first flat wire is flush with the end of the slot facing the first flat wire. This means that the blocking portion is located inside the slot and does not occupy the space between the end of the slot facing the first flat wire and the first flat wire, thus ensuring the radial dimension of the channel along the motor stator. Compared to a portion of the blocking portion extending into the space between the slot and the first flat wire, the blocking portion being located inside the slot increases the channel area, increasing the flow rate of coolant through the channel per unit time, thereby improving the heat dissipation efficiency of the flat wire in the stator slot.

[0039] In some embodiments, the distance between the end of the blocking portion facing the first flat wire and the first flat wire is less than the distance between the end of the slot facing the first flat wire and the first flat wire. This can be understood as a portion of the blocking portion being located between the end of the slot facing the first flat wire and the first flat wire. The portion of the blocking portion extending between the slot and the first flat wire increases the strength of the support portion, ensuring the support force of the support portion on the first flat wire. Furthermore, it reduces the contact area between the support portion and the first flat wire, increasing the circumferential dimension of the channel along the motor stator, thereby improving the heat dissipation efficiency of the flat wire.

[0040] In one embodiment, the slot includes a first slot segment and a second slot segment that are connected to each other. The second slot segment is located at the end of the first slot segment facing the first flat wire. The size of the second slot segment gradually decreases along the radial direction of the motor stator from the direction of the second slot segment toward the first slot segment.

[0041] From the first slot segment toward the second slot segment, the second slot segment gradually increases in size along the circumference of the motor stator. Correspondingly, the sealing portion also gradually increases in size along the circumference of the motor stator to increase its strength. Since the support portion is located at the end of the sealing portion away from the slot opening, the increased strength of the sealing portion leads to an increase in the strength of the support portion, resulting in a higher load-bearing capacity for the flat wire.

[0042] In one embodiment, the cross-sectional shape of the groove wedge includes a cross shape, a Y shape, or a T shape.

[0043] In some embodiments, the cross-sectional shape of the slot wedge is cross-shaped. In other embodiments, the cross-sectional shape of the slot wedge is Y-shaped.

[0044] In other embodiments, the cross-sectional shape of the slot wedge is T-shaped.

[0045] In one embodiment, the groove wedge is an integrally injection-molded structural component.

[0046] By using a one-piece injection molding process to form a groove wedge at the groove opening, the wedge serves two purposes: it seals the groove opening and it provides cooling oil channels for the flat wire. Furthermore, the one-piece injection molding process for manufacturing the groove wedge is easy to implement and increases mass production reliability.

[0047] A second aspect of this application provides a powertrain including a reducer and the aforementioned flat wire motor, wherein the flat wire motor is connected to the reducer in a transmission manner.

[0048] Flat wire motors are used to convert electrical energy into rotational mechanical energy and output torque to a reducer. The reducer is used to reduce the speed, increase the torque, and transmit the power to the transmission mechanism, and then to the wheels to drive the wheels to rotate.

[0049] In addition, the powertrain provided in this application includes the aforementioned flat wire motor. Therefore, the powertrain provided in this application solves the same technical problem and has the same technical effect as the flat wire motor in the above-mentioned technical solution, and will not be repeated here.

[0050] A third aspect of this application provides a vehicle including wheels and the aforementioned powertrain for driving the wheels.

[0051] The powertrain is used to convert electrical energy into mechanical energy and drive the wheels to rotate, thereby enabling the vehicle to move. Furthermore, the powertrain provided in this application includes the aforementioned powertrain; therefore, the vehicle provided in this application solves the same technical problem and has the same technical effect as the powertrain of the aforementioned technical solution, and will not be elaborated further here. Attached Figure Description

[0052] Figure 1 A schematic diagram of the structure of a vehicle provided in an embodiment of this application;

[0053] Figure 2 This is a schematic diagram of the structure of a powertrain provided in an embodiment of this application;

[0054] Figure 3 A partial exploded view of a flat wire motor provided in an embodiment of this application;

[0055] Figure 4 This application provides a schematic diagram of the structure of a stator core in an electric motor stator.

[0056] Figure 5 This is one of the partial structural schematic diagrams of a motor stator provided in an embodiment of this application;

[0057] Figure 6 This is a schematic diagram of the structure of an insulating paper provided in an embodiment of this application;

[0058] Figure 7 This is a second partial structural schematic diagram of a motor stator provided in an embodiment of this application;

[0059] Figure 8 This is the third partial structural schematic diagram of a motor stator provided in an embodiment of this application;

[0060] Figure 9 This is the fourth partial structural schematic diagram of a motor stator provided in the embodiments of this application;

[0061] Figure 10 Fifth schematic diagram of a partial structure of a motor stator provided in this application embodiment;

[0062] Figure 11 This is the sixth partial structural schematic diagram of a motor stator provided in the embodiments of this application.

[0063] Figure label:

[0064] 1000-Vehicle; 100-Powertrain; 200-Wheel; 300-Transmission mechanism; 10-Flat wire motor; 20-Reducer; 01-Motor stator; 02-Motor rotor; 021-Rotor core; 1-Stator core; 11-Stator slot; 111-Slot opening; 1111-First slot segment; 1112-Second slot segment; 2-Stator winding; 21-Flat wire; 211-First flat wire; 3-Insulating paper; 4-Slot wedge; 41-Support part; 42-Blocking part; 5-Gap; 6-Channel. Detailed Implementation

[0065] The technical solutions of the embodiments of this application will be described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments.

[0066] In the accompanying drawings of the embodiments of this application, solid structures such as parts and components are represented by guide lines; hollow structures such as openings, holes, spaces, and cavities are represented by guide lines with arrows.

[0067] This application provides a vehicle that is a new energy vehicle powered by electricity. In some embodiments, the new energy vehicle is a pure electric vehicle, a hybrid electric vehicle, or a fuel cell electric vehicle. In other embodiments, the new energy vehicle is a vehicle that uses a high-efficiency energy storage device such as a supercapacitor, flywheel battery, or flywheel energy storage device as its power source.

[0068] Figure 1 This is a structural schematic diagram of a vehicle provided as an embodiment of this application. (Refer to...) Figure 1 The vehicle 1000 includes wheels 200 and a powertrain 100, which drives the vehicle 1000 to rotate, thereby enabling the vehicle 1000 to move.

[0069] Reference Figure 1 The vehicle 1000 also includes a transmission mechanism 300, which is used to drive the powertrain 100 and the wheels 200. The powertrain 100 converts electrical energy into mechanical energy and drives the wheels 200 to rotate through the transmission mechanism 300, thereby enabling the vehicle 1000 to move.

[0070] exist Figure 1 In the given embodiment, the powertrain 100 is used to drive the rear wheels (wheels 200 on the side closest to the rear of the vehicle) of the vehicle 1000 to rotate, and the front wheels of the vehicle 1000 are used to achieve steering. The vehicle 1000 is more responsive when steering and more stable when cornering.

[0071] In other embodiments, the powertrain 100 is used to drive the front wheels (wheels 200 on the side closest to the front of the vehicle) of the vehicle 1000 to rotate. The front wheels are used to achieve driving and steering. The front-wheel drive system has a simple structure, fewer parts, lighter weight, reduced power loss, higher transmission efficiency, and lower fuel consumption and cost.

[0072] Figure 2 This is a schematic diagram of a powertrain provided in an embodiment of this application. (Refer to...) Figure 2 The structure shown in the dashed box is the powertrain 100, which includes a flat wire motor 10 and a reducer 20. The flat wire motor 10 and the reducer 20 are connected in a transmission connection. The flat wire motor 10 converts electrical energy into rotational mechanical energy and outputs torque to the reducer 20. The reducer 20 includes a gear set (not shown). The reducer 20 reduces the rotational speed and increases the torque through the gear set, transmitting power to the transmission mechanism 300, and then to the wheel 200 to drive the wheel 200 to rotate.

[0073] Figure 3 This is a partial exploded view of a flat wire motor provided in an embodiment of this application. (Refer to...) Figure 3 The flat wire motor 10 includes a motor stator 01 and a motor rotor 02, which work together to convert electrical energy into mechanical energy. The motor stator 01 includes a stator core 1 and a stator winding 2, with the stator winding 2 mounted on the stator core 1. The motor rotor 02 includes a rotor core 021 and a rotor winding (not shown), with the rotor winding mounted on the rotor core 021.

[0074] When the stator winding 2 is energized, it generates a rotating magnetic field. The rotor winding of the motor rotor 02 cuts the magnetic field, generating an induced current. The induced current interacts with the rotating magnetic field to form an electromagnetic torque. Under the action of the electromagnetic torque, the motor rotor 02 rotates, thereby realizing the conversion of electrical energy into mechanical energy.

[0075] In some embodiments, both the rotor core 021 and the stator core 1 are made of multiple silicon steel sheets stacked together to reduce the energy loss of the stator core 1 and the rotor core 021 due to hysteresis and eddy current effects under the action of an alternating magnetic field.

[0076] Figure 4 This is a schematic diagram of the stator core in a motor stator provided as an embodiment of this application. (Refer to...) Figure 3 and Figure 4 The stator core 1 includes multiple stator slots 11, which are spaced apart along the circumference of the motor stator 01. The circumference of the motor stator is as follows: Figure 4 As shown in direction A on the diagram.

[0077] Reference Figure 3 and Figure 4 Each stator slot 11 is used to accommodate multiple flat wires 21, and all the flat wires 21 in the multiple stator slots 11 are connected to form a stator winding 2.

[0078] In some embodiments, the flat wire 21 is a copper flat wire. Copper has good electrical conductivity, high strength, is easy to process and form, has good thermal conductivity and good stability. The use of flat copper wire in the flat wire motor improves the efficiency of the flat wire motor and reduces power loss and heat generation.

[0079] Figure 5 This is one of the partial structural schematic diagrams of a motor stator provided in an embodiment of this application. (Refer to...) Figure 5 The multiple flat wires 21 within the stator slot 11 are arranged in layers sequentially along the radial direction of the motor stator. The radial direction of the motor stator is as follows: Figure 5 As shown in direction B on the diagram.

[0080] Reference Figure 5Insulating paper 3 is installed inside the stator slot 11, and the insulating paper 3 surrounds the outer periphery of multiple flat wires 21 inside the stator slot 11. On the one hand, the insulating paper 3 is used to isolate the electrical connection between the multiple flat wires 21 and the stator core 1, avoiding direct contact between the multiple flat wires 21 and the stator core 1, which could lead to short circuits or leakage, thus ensuring the safety and performance of the flat wire motor. On the other hand, the insulating paper 3 is used to fill the gaps between the stator slot 11 and the multiple flat wires 21, ensuring the geometric shape of the multiple flat wires 21 within the stator slot 11, and preventing the multiple flat wires 21 from shifting or deforming during vibration or thermal expansion.

[0081] During the operation of the flat wire motor, when current flows through the flat wire 21, the resistance of the flat wire 21 causes it to heat up. The increased temperature of the flat wire 21 further increases its resistance, causing its temperature to rise continuously. Excessive temperature of the flat wire 21 not only damages its service life and reduces the working efficiency of the flat wire motor, but may even cause electrical faults and safety accidents.

[0082] To improve the heat dissipation performance of flat wire 21, Figure 6 This is a schematic diagram of the structure of an insulating paper provided in an embodiment of this application. (Refer to...) Figure 5 and Figure 6 The insulating paper 3 is a single layer. Single-layer insulating paper 3 should be understood as insulating paper 3 without overlap or splicing. Compared to solutions with overlapping or splicing insulating paper 3, single-layer insulating paper 3 eliminates the overlapping or splicing portions, reducing the space occupied by insulating paper 3 in the stator slot 11, thereby increasing the space occupied by flat wire 21 in the stator slot 11. The increased space occupied by flat wire 21 in the stator slot 11 results in higher current density and magnetic flux density in the flat wire motor 10, thus improving the efficiency and power density of the flat wire motor 10. Furthermore, it increases the contact area between the flat wire 21 and the heat-conducting materials such as the impregnating varnish in the stator slot 11, improving the heat conduction efficiency of the flat wire 21 in the stator slot 11, thereby improving the heat dissipation performance of the motor stator.

[0083] In embodiments where the flat wire 21 is made of copper, the increased space occupied by the flat wire 21 within the stator slot 11 should be understood as an increase in copper fill factor. Copper fill factor refers to the ratio between the cross-sectional area of ​​the copper flat wire 21 filling the stator slot 11 and the effective cross-sectional area of ​​the stator winding 2. The single layer of insulating paper 3 improves both the efficiency and power density of the flat wire motor, while also increasing the heat conduction efficiency of the flat wire 21 within the stator slot 11, thereby improving the heat dissipation performance of the motor stator.

[0084] In some embodiments, the surface of the insulating paper 3 is flat and of uniform thickness along the outer periphery of the plurality of flat wires 21 in the stator slot 11.

[0085] The smooth surface of the insulating paper 3 reduces the friction between the insulating paper 3 and the flat wire 21. When the flat wire 21 is embedded in the stator slot 11, the friction is reduced, the embedding speed of the flat wire 21 is higher, and the production efficiency is improved.

[0086] The uniform thickness of the insulating paper 3 ensures that it can withstand voltage evenly in an electric field, avoiding local electric field concentration and reducing the risk of the insulating paper 3 being broken down. On the other hand, it also prevents the flat wire 21 from being too tight or too loose in some areas during the winding process, reducing the risk of the flat wire 21 being deformed.

[0087] To prevent insulation between the flat wires 21, the gaps between the flat wires 21, the gaps between the insulating paper 3 and the stator slot 11, and the gap between the flat wires 21 and the insulating paper 3 are filled with impregnating varnish (not shown). The impregnating varnish is an insulating varnish. This ensures a smooth surface and uniform thickness of the insulating paper 3, reducing the flow resistance of the varnish and air bubbles in the varnish. It also promotes uniform and dense varnish layer thickness after curing, preventing insulation failure caused by uneven varnish layer thickness.

[0088] In this embodiment, filling the gaps with impregnating varnish reduces the risk of short circuits caused by electrical breakdown gaps and improves the insulation performance of the flat wire motor. On the other hand, after the impregnating varnish cures, it fixes the flat wire 21 and the insulating paper 3 in the stator slot 11, preventing the flat wire 21 from moving and wearing out in the stator slot 11, and also improving the vibration resistance and impact resistance of the stator winding.

[0089] In some embodiments, the impregnating varnish cures to form a highly thermally conductive resin layer, which effectively conducts the heat generated by the flat wire 21 during operation and improves the heat dissipation efficiency of the flat wire 21.

[0090] In some embodiments, the insulating paper 3 is an integrally formed structural component. This serves two purposes: firstly, it eliminates overlapping or overlapping portions of the existing insulating paper 3, reducing the space occupied by the insulating paper 3 within the stator slot 11, thereby increasing the space occupied by the flat wire 21 within the stator slot 11. Secondly, it facilitates the insertion of the insulating paper 3 into the stator slot 11, reducing assembly steps and improving assembly efficiency.

[0091] Reference Figure 6 The cross-sectional shape of the insulating paper 3 is the same as that of the stator slot 11, both being rectangular. The cross-sectional shape of the insulating paper refers to the shape of the planar figure presented along the radial direction of the motor stator.

[0092] Before assembly, the insulating paper 3 is pre-formed into a rectangular frame structure. During assembly, the insulating paper 3 is inserted into the stator slot 11, followed by the winding process of the flat wire 21. The assembly is simple and quick, which helps to improve assembly efficiency.

[0093] Reference Figure 5The stator slot 11 includes a slot opening 111 and a slot bottom (not shown), which are arranged opposite each other along the radial direction of the motor stator 01. The slot opening 111 is located on the side of the stator slot 11 facing the motor rotor 02, and the slot bottom is located on the side of the stator slot 11 away from the slot opening 111.

[0094] During the operation of the flat wire motor, the magnetic field distortion at the slot opening 111 of the stator slot 11 is severe, causing large eddy currents and circulating currents to be induced in the flat wire 21 near the slot opening 111. This increases the loss of the flat wire 21 at the slot opening 111, resulting in severe heating of the flat wire 21 at the slot opening 111. Furthermore, due to the skin effect, the loss of the flat wire 21 at the slot opening 111 of the stator slot 11 is more than twice that at the bottom of the stator slot 11.

[0095] To improve the heat dissipation performance of the motor stator 01, the flat wire 21 at the slot 111 needs to be cooled. Figure 7 This is a second partial structural schematic diagram of a motor stator provided in an embodiment of this application. (Refer to...) Figure 7 Stator slot 11 faces the motor rotor 02 (e.g.) Figure 3 One end of the stator slot 11 (as shown) is provided with a slot 111 and a slot wedge 4. Multiple flat wires 21 within the stator slot 11 include a first flat wire 211. The distance between the first flat wire 211 and the slot wedge 4 is less than the distance between the other flat wires 21 within the stator slot 11 and the slot wedge 4. Because the multiple flat wires 21 within each stator slot 11 are along the motor stator 01 (as shown) Figure 3 As shown, the radial layers are arranged sequentially, so the first flat line 211 is the flat line 21 closest to the slot 111 among the multiple flat lines 21.

[0096] The slot wedge 4 is used to seal the slot opening 111 and to support the first flat wire 211. Since the first flat wire 211 is the one closest to the slot opening 111 among the multiple flat wires 21, the slot wedge 4 supports the first flat wire 211, which in turn supports the other flat wires 21 within the stator slot 11. The slot wedge 4 provides mechanical support for the first flat wire 211 and bears the electromagnetic force and mechanical stress generated by the flat wire 21 during operation, preventing deformation or damage. Furthermore, the slot wedge 4 fixes the multiple flat wires 21 within the stator slot 11, preventing displacement of the flat wires 21 due to centrifugal or electromagnetic forces during flat wire motor operation, reducing the risk of vibration and noise caused by flat wire displacement. Additionally, the slot wedge 4 fills the gap between the flat wires 21 and the stator slot 11, reducing air gaps and the risk of partial discharge.

[0097] exist Figure 7In the given embodiment, a gap 5 exists between the slot wedge 4 and the first flat wire 211, which serves as a channel 6 for coolant flow. Because the flat wire 21 at the slot opening 111 experiences significant heat generation, the gap between the slot wedge 4 and the first flat wire 211 is used as the coolant flow channel 6. During the flow of the coolant within the channel 6, the coolant directly contacts the first flat wire 211 to remove its heat, thereby reducing the temperature and heat loss of the first flat wire 211 at the slot opening 111 and improving the heat dissipation efficiency of the motor stator.

[0098] In some embodiments, the slot wedge 4 is made of materials with good thermal conductivity, such as epoxy glass cloth, phenolic laminated glass cloth, and ceramic fiber reinforced composite material, so that the slot wedge 4 has good thermal conductivity and further improves the heat dissipation efficiency of the flat wire 21 at the slot opening 111.

[0099] In some embodiments, at least one support portion 41 is provided at one end of the slot wedge 4 facing the first flat wire 211. The support portion 41 is used to support the first flat wire 211. The dimension of the support portion 41 along the circumference of the motor stator 01 is smaller than the dimension of the first flat wire 211 along the circumference of the motor stator 01, ensuring that a gap 5 is formed between the other part of the slot wedge 4 (excluding the support portion 41) and the first flat wire 211, so that a channel 6 for coolant flow can be formed through the gap 5 between the other part of the slot wedge 4 (excluding the support portion 41) and the first flat wire 211.

[0100] Reference Figure 7 A support portion 41 is provided at one end of the slot wedge 4 facing the first flat wire 211, and this support portion 41 is used to support the first flat wire 211. The channel 6 is located between the support portion 41 and the circumferential groove wall of the stator slot 11. The circumferential groove wall of the stator slot 11 is the groove wall of the stator slot 11 along the circumference of the motor stator. Wherein, the circumferential direction of the motor stator is as follows... Figure 7 As shown in direction A on the middle map.

[0101] Reference Figure 7 The support portion 41 is used to support the first flat wire 211 at the middle position along the circumference of the motor stator. The support point is located at the middle position of the first flat wire 211 along the circumference of the motor stator. Compared with the support portion 41 supporting the first flat wire 211 at other positions, the support portion 41 with the same cross-sectional size supporting the middle position has a higher load-bearing capacity, the first flat wire 211 is subjected to more uniform force, the local stress concentration of the first flat wire 211 is reduced, and the stability is higher.

[0102] Under the same supporting force, the cross-sectional dimension of the support portion 41 supported in the middle position is smaller than that of the support portion 41 supported in other positions. Therefore, under the same supporting force, by supporting the support portion 41 in the middle position, the cross-sectional dimension of the support portion 41 is reduced, the space occupied by the support portion 41 and the amount of material used by the support portion 41 are both reduced, resulting in lower cost and smaller space occupation.

[0103] exist Figure 7 In the given embodiment, the gaps between the two ends of the circumferential support portion 41 of the motor stator and the groove walls of the stator slot 11 are respectively used as a channel 6. Since the dimension of the support portion 41 along the circumferential direction of the motor stator is smaller than the dimension of the first flat wire 211 along the circumferential direction of the motor stator, the gaps 5 between the two ends of the circumferential direction of the support portion 41 (the two ends of the support portion 41 along the circumferential direction of the motor stator) and the two circumferential groove walls of the stator slot 11 (the two groove walls of the stator slot 11 along the circumferential direction of the motor stator) are also the gaps between the two ends of the first flat wire 211 and the other parts of the slot wedge 4 except for the support portion 41.

[0104] A channel 6 is formed by the circumferential end of the support portion 41, one circumferential groove wall of the stator slot 11, the first flat wire 211, and the remaining parts of the slot wedge 4 (excluding the support portion 41). Another channel 6 is formed by the other circumferential end of the support portion 41, another circumferential groove wall of the stator slot 11, the first flat wire 211, and the remaining parts of the slot wedge 4 (excluding the support portion 41). By providing two channels 6, the contact area between the coolant and the flat wire 21 is increased, further improving the heat dissipation efficiency of the flat wire 21 at the slot opening 111, thereby further improving the heat dissipation efficiency of the motor stator. This is suitable for flat wire motors where the flat wire 21 at the slot opening 111 generates significant heat.

[0105] In this embodiment, there are two channels 6, and the sum of the dimensions of the two channels 6 along the circumferential direction of the motor stator is greater than the dimension of the support portion 41 along the circumferential direction of the motor stator. By ensuring that the sum of the dimensions of the two channels 6 along the circumferential direction of the motor stator is greater than the dimension of the support portion 41 along the circumferential direction of the motor stator, the contact area between the coolant in the channel 6 and the first flat wire 211 is greater than the contact area between the support portion 41 and the first flat wire 211, thereby improving the heat dissipation efficiency of the coolant on the first flat wire 211.

[0106] In other embodiments, the gap 5 between one end of the circumferential support portion 41 of the motor stator and the slot wall of the stator slot 11 serves as a channel 6. The circumferential end of the support portion 41, one circumferential slot wall of the stator slot 11, the first flat wire 211, and the remaining portions of the slot wedge 4 (excluding the support portion 41) enclose a channel 6. By providing a channel 6, the heat dissipation efficiency of the flat wire 21 at the slot opening 111 is improved, making it suitable for flat wire motors where the heat generated by the flat wire 21 at the slot opening 111 is relatively low.

[0107] In this embodiment, channel 6 is included, and the dimension of channel 6 along the circumference of the motor stator is larger than the dimension of support portion 41 along the circumference of the motor stator. By making the dimension of channel 6 along the circumference of the motor stator larger than the dimension of support portion 41 along the circumference of the motor stator, the contact area between the coolant in channel 6 and the first flat wire 211 is ensured to be larger than the contact area between support portion 41 and the first flat wire 211, thereby improving the heat dissipation efficiency of the coolant on the first flat wire 211.

[0108] Figure 8 This is the third partial structural schematic diagram of a motor stator provided in an embodiment of this application. Figure 7 The difference between the embodiments shown is that, Figure 8 In the illustrated embodiment, the support portion 41 includes two parts, which are respectively used to support the two ends of the first flat wire 211 along the circumferential direction of the motor stator 01, and the gap 5 between the two support portions 41 serves as a channel 6.

[0109] Two support parts 41 support both ends of the first flat wire 211 along the circumferential direction of the motor stator, providing support force to the first flat wire 211 and ensuring its stability. Since multiple flat wires 21 in each stator slot 11 are arranged in layers along the radial direction of the motor stator, supporting the first flat wire 211 with the two support parts 41 also supports the other flat wires 21 in the stator slot 11.

[0110] In this embodiment, the gap 5 between the two support portions 41 serves as a channel 6, allowing the middle position of the first flat wire 211 to contact the coolant. Since the heat dissipation efficiency of the middle position of the first flat wire 211 is low, the coolant preferentially cools the middle position of the first flat wire 211 to achieve rapid cooling of the first flat wire 211.

[0111] exist Figure 8 In the illustrated embodiment, the dimension of channel 6 along the circumference of the motor stator is smaller than the dimension of the first flat wire 211 along the circumference of the motor stator. Since each support portion 41 supports the first flat wire 211, the dimension of channel 6 along the circumference of the motor stator is smaller than the dimension of the first flat wire 211 along the circumference of the motor stator, thus ensuring stable support of the first flat wire 211 by the support portion 41.

[0112] Reference Figure 5 , Figure 7 and Figure 8The slot wedge 4 includes a blocking portion 42, which is connected to the support portion 41. The blocking portion 42 is used to block the slot opening 111. The distance between the end of the blocking portion 42 facing the first flat wire 211 and the first flat wire 211 is less than the distance between the end of the slot opening 111 facing the first flat wire 211 and the first flat wire 211. This means that a portion of the blocking portion 42 is located between the end of the slot opening 111 facing the first flat wire 211 and the first flat wire 211. The portion of the blocking portion 42 extending between the slot opening 111 and the first flat wire 211 increases the strength of the support portion 41, ensuring the support force of the support portion 41 on the first flat wire 211. Furthermore, it reduces the contact area between the support portion 41 and the first flat wire 211, increasing the circumferential dimension of the channel 6 along the motor stator, thereby improving the heat dissipation efficiency of the flat wire 21.

[0113] Figure 9 This is the fourth partial structural schematic diagram of a motor stator provided in an embodiment of this application. Figure 7 The difference between the embodiments shown is that, Figure 9 In the illustrated embodiment, the end of the blocking portion 42 facing the first flat wire 211 is flush with the end of the slot 111 facing the first flat wire 211. This means that the blocking portion 42 is located inside the slot 111 and does not occupy the space between the end of the slot 111 facing the first flat wire 211 and the first flat wire 211, thus ensuring the radial dimension of the channel 6 along the motor stator. Compared to a portion of the blocking portion 42 extending into the space between the slot 111 and the first flat wire 211, the blocking portion 42 being located inside the slot 111 increases the area of ​​the channel 6, increasing the flow rate of coolant through the channel 6 per unit time, thereby improving the heat dissipation efficiency of the flat wire 21 in the stator slot 11.

[0114] Figure 10 This is the fifth partial structural schematic diagram of a motor stator provided in an embodiment of this application. Figure 8 The difference between the embodiments shown is that, Figure 10 In the illustrated embodiment, the end of the blocking portion 42 facing the first flat line 211 is flush with the end of the slot 111 facing the first flat line 211. The advantage of the end of the blocking portion 42 facing the first flat line 211 being flush with the end of the slot 111 facing the first flat line 211 has been described above and will not be repeated here.

[0115] Figure 11 This is the sixth partial structural schematic diagram of a motor stator provided in an embodiment of this application. (Refer to...) Figure 11 The slot 111 includes a first slot segment 1111 and a second slot segment 1112. The second slot segment 1112 is located at the end of the first slot segment 1111 facing the first flat wire 211. The size of the second slot segment 1112 gradually decreases along the circumferential direction of the motor stator from the direction of the second slot segment 1112 toward the first slot segment 1111.

[0116] From the direction of the second slot 1112 toward the first slot 1111, the second slot 1112 is along the circumference of the motor stator (e.g.) Figure 11 The dimensions of the section 1112 (shown in direction A) gradually decrease, which can be understood as follows: from the first slot 1111 towards the second slot 1112, the dimensions of the second slot 1112 gradually increase along the circumferential direction of the motor stator. Correspondingly, the dimensions of the sealing portion 42 gradually increase along the circumferential direction of the motor stator to increase the strength of the sealing portion 42. Since the support portion 41 is located at the end of the sealing portion 42 opposite to the slot opening 111, the increased strength of the sealing portion 42 also increases the strength of the support portion 41, resulting in a higher load-bearing capacity of the support portion 41 for the flat wire 21.

[0117] The cross-sectional shape of the groove wedge 4 provided in this application is varied, among which... Figure 7 and Figure 9 In the embodiment shown, the cross-sectional shape of the groove wedge 4 is cross-shaped. Figure 8 and Figure 10 In the illustrated embodiment, the cross-sectional shape of the slot wedge 4 is Y-shaped. In other embodiments, the cross-sectional shape of the slot wedge 4 is T-shaped. Those skilled in the art can design selectively according to actual needs.

[0118] In some embodiments, the slot wedge 4 is a one-piece injection molded structural component. The slot wedge 4 is formed in the slot opening 111 using a one-piece injection molding process. On the one hand, the slot wedge 4 seals the slot opening 111; on the other hand, it provides cooling oil channels for the flat wire 21. Furthermore, the one-piece injection molding process for machining the slot wedge 4 is easy to implement, increasing mass production reliability.

[0119] The above are merely specific embodiments of this application, but the scope of protection of this application is not limited thereto. Any changes or substitutions within the technical scope disclosed in this application should be included 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. A flat wire motor, characterized in that, The flat wire motor includes a motor stator and a motor rotor. The motor stator includes multiple stator slots, which are spaced apart circumferentially along the motor stator. Each stator slot is used to accommodate multiple flat wires, and the multiple flat wires in each stator slot are arranged in layers sequentially along the radial direction of the motor stator, wherein: Each of the stator slots is provided with insulating paper, and a single layer of insulating paper surrounds the outer periphery of the plurality of flat wires in the stator slot.

2. The flat wire motor according to claim 1, characterized in that, The surface of the insulating paper along the outer periphery of the plurality of flat wires in the stator slot is flat and of uniform thickness.

3. The flat wire motor according to claim 1, characterized in that, The insulating paper is a one-piece molded structural component.

4. The flat wire motor according to any one of claims 1-3, characterized in that, The stator slot is provided with a slot opening and a slot wedge at one end facing the motor rotor. The plurality of flat wires in the stator slot include a first flat wire. The distance between the first flat wire and the slot wedge is smaller than the distance between the other flat wires in the stator slot and the slot wedge. The groove wedge is used to seal the groove opening and to support the first flat wire. There is a gap between the groove wedge and the first flat wire, which serves as a channel for coolant flow.

5. The flat wire motor according to claim 4, characterized in that, The slot wedge has at least one support portion at one end facing the first flat wire. The support portion is used to support the first flat wire, and the dimension of the support portion along the circumferential direction of the motor stator is smaller than the dimension of the first flat wire along the circumferential direction of the motor stator.

6. The flat wire motor according to claim 5, characterized in that, The support portion includes one component, which supports the first flat wire at the middle position along the circumference of the motor stator. The gap between at least one end of the support portion and the groove wall of the stator slot along the circumference of the motor stator serves as a channel.

7. The flat wire motor according to claim 6, characterized in that, The dimension of the channel along the circumference of the motor stator is greater than the dimension of the support portion along the circumference of the motor stator.

8. The flat wire motor according to claim 5, characterized in that, The support portion includes two parts, which are respectively used to support the two ends of the first flat wire along the circumferential direction of the motor stator, and the gap between the two support portions serves as a channel.

9. The flat wire motor according to claim 8, characterized in that, The dimension of the channel along the circumference of the motor stator is smaller than the dimension of the first flat wire along the circumference of the motor stator.

10. The flat wire motor according to claim 5, characterized in that, The groove wedge includes a blocking portion connected to the supporting portion. The blocking portion is used to block the groove opening, and the end of the blocking portion facing the first flat line is at least flush with the end of the groove opening facing the first flat line.

11. The flat wire motor according to claim 4, characterized in that, The slot includes a first slot segment and a second slot segment that are connected to each other. The second slot segment is located at the end of the first slot segment facing the first flat wire. The size of the second slot segment gradually decreases along the circumferential direction of the motor stator from the direction of the second slot segment toward the first slot segment.

12. The flat wire motor according to claim 4, characterized in that, The cross-sectional shape of the groove wedge includes a cross shape, a Y shape, or a T shape.

13. The flat wire motor according to claim 4, characterized in that, The groove wedge is an integral injection-molded structural component.

14. A powertrain, characterized in that, The powertrain includes a reducer and a flat wire motor as described in any one of claims 1-13, wherein the flat wire motor is drive-connected to the reducer.

15. A vehicle, characterized in that, The vehicle includes wheels and the powertrain of claim 14, the powertrain being used to drive the wheels.

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