Plastic-encapsulated stators and motors

Abstract

This utility model discloses a plastic-encapsulated stator, comprising: a wound stator having multiple pins; a plastic-encapsulated body, which is plastic-coated around the outside of the wound stator and has a stepped structure for exposing the pins, the stepped structure having a limiting portion protruding radially inward; a connecting wire assembly, which is arranged along the end face of the stepped structure and connected to the pins, the limiting portion being located outside the connecting wire assembly; and an upper end cover, which is disposed on the end of the plastic-encapsulated body near the pins and spaced apart from the pins and the connecting wire assembly. This utility model's plastic-encapsulated stator and motor, through the limiting portion radially limiting the connecting wire assembly, increases the radial distance between the connecting wire assembly and the inner wall of the stator, avoiding safety hazards caused by insufficient creepage distance.

Description

Technical Field

[0001] This utility model relates to the field of motor technology, and in particular to a plastic-encapsulated stator and motor. Background Technology

[0002] Permanent magnet brushless DC motors are becoming increasingly widely used due to their advantages such as high efficiency and energy saving. Their use in air conditioning, replacing traditional AC induction motors, is a necessity driven by the energy-saving trend in recent years.

[0003] A permanent magnet brushless DC motor consists of a stator assembly, rotor assembly, end covers, power line assembly, and insulation system. The stator assembly is mainly composed of a stator core, enameled wire, pins, end covers, and BMC molding compound. After installation, the stator assembly must meet certain insulation requirements between itself and the electronic wire terminals and end covers. The existing solution is to add heat shrink tubing for insulation at the connection between the power line and the terminal, but this insulation structure is very expensive, difficult to manufacture, and has low assembly efficiency. Utility Model Content

[0004] The technical problem to be solved by this utility model is: in order to solve the technical problems of complex structure, difficult assembly and insufficient creepage distance in the prior art, this utility model provides a plastic-encapsulated stator and motor, which increases the radial distance between the connecting wire assembly and the inner wall of the stator by limiting the connecting wire assembly radially through the limiting part, so as to avoid safety hazards caused by insufficient creepage distance.

[0005] The technical solution adopted by this utility model to solve its technical problem is: a plastic-encapsulated stator, comprising:

[0006] A wound stator having a plurality of pins;

[0007] A molding compound, which is molded over the outside of a wound stator and has a stepped structure for protruding pins, the stepped structure having a limiting portion that protrudes radially inward;

[0008] A connecting wire assembly, wherein the connecting wire assembly is arranged along the end face of the stepped structure and connected to the pin, and the limiting part is located on the outside of the connecting wire assembly;

[0009] The upper end cap is disposed on the end of the plastic seal near the pin and spaced apart from the pin and the connecting wire assembly.

[0010] This utility model features a plastic-encapsulated stator that uses a limiting part to contact and limit the connection wire assembly, thereby keeping the connection wire assembly radially away from the inner wall of the stator. This increases the distance between the two, prevents them from contacting each other, increases the creepage distance and electrical clearance of the motor, and avoids safety hazards caused by insufficient creepage distance.

[0011] Furthermore, the connector assembly includes electronic wires electrically connected to pins via terminals, with the terminals corresponding to the limiting portion. This eliminates the need for heat-shrink tubing on the terminals, reducing processing costs and complexity. Additionally, it eliminates the need to adjust the terminal positions during installation, thereby improving production efficiency and ensuring the consistency of the connector assembly.

[0012] Furthermore, to increase insulation capability, the connecting wire assembly includes electronic wires electrically connected to pins via terminals, the terminals having heat-shrink tubing on their outer sides, a portion of which abuts against a limiting portion.

[0013] Furthermore, in order to further limit the positioning of the connecting wire assembly, the limiting part includes a boss that abuts against a terminal or heat shrink tubing.

[0014] Furthermore, in order to meet the creepage distance requirements, the upper end of the encapsulation is connected to an upper end cap, and there is a gap between the upper end cap and the pin. The radial width of the boss is greater than 10% of the axial distance between the terminal and the upper end cap.

[0015] Furthermore, in order to ensure that the connecting wire assembly has sufficient installation space and to avoid contact with the rotor, the radial width of the boss is 1-2 mm.

[0016] Furthermore, to avoid the electron wires becoming scattered, the electron wires are bundled together using a sleeve.

[0017] Furthermore, in order to bring out the connecting wire assembly, the encapsulation is also provided with a wire exit clip, and the electronic wire extends from the pin to the wire exit clip and passes through the wire exit clip within the stepped structure.

[0018] Furthermore, in order to isolate the end cap and the connecting wire assembly, an insulating gasket is provided within the stepped structure, the insulating gasket being located between the upper end cap and the connecting wire assembly.

[0019] Furthermore, to ensure product dimensions and processing progress, the boss and the encapsulation body are integrally injection molded from BMC material.

[0020] Another technical solution adopted by this utility model to solve its technical problem is:

[0021] Compared with the prior art, the beneficial effects of this utility model are: an electric motor, including a rotor and the above-mentioned encapsulated stator.

[0022] 1. The present invention provides a plastic-encapsulated stator and motor, which adds a limiting part to the plastic-encapsulated body. The limiting part limits the radial position of the connecting wire assembly, preventing the connecting wire assembly from getting close to the inner wall of the stator, increasing the creepage distance and electrical clearance, and reducing safety hazards.

[0023] 2. The plastic-encapsulated stator and motor of this utility model have bosses with a certain width and close to the terminals. While ensuring the creepage distance, they reserve sufficient installation space for the connecting wire assembly. This can avoid interference between the connecting wire assembly and the rotor due to insufficient radial space, ensure product consistency, reduce assembly difficulty, and improve production efficiency.

[0024] 3. The stator and motor of this utility model are encapsulated in plastic. The encapsulation body and the boss are integrally injection molded using BMC material to ensure dimensional accuracy. Attached Figure Description

[0025] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0026] Figure 1 This is a cross-sectional view of the plastic-encapsulated stator of this utility model;

[0027] Figure 2 yes Figure 1 A magnified view of a portion of the image;

[0028] Figure 3 This is a schematic diagram of the three-dimensional structure of the encapsulated body;

[0029] Figure 4 for Figure 4 Top view;

[0030] Figure 5 This is a schematic diagram of the structure of a plastic-encapsulated stator according to another embodiment of the present invention.

[0031] In the diagram: 1. Winding stator, 11. Pin, 2. Encapsulated body, 21. Stepped structure, 22. Limiting part, 3. Connecting wire assembly, 31. Electronic wire, 32. Terminal, 33. Outlet clamp, 34. Sleeve, 35. Heat shrink tubing, 4. Insulating gasket, 5. Upper end cover, 6. Lower end cover. Detailed Implementation

[0032] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, illustrating only the basic structure of the present invention, and therefore only show the components relevant to the present invention.

[0033] In the description of this utility model, it should be understood that the terms "center," "longitudinal," "transverse," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential," etc., indicating the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. Furthermore, features defined with "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, unless otherwise stated, "a plurality of" means two or more.

[0034] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0035] like Figures 1 to 4 As shown, a molded stator includes: a wound stator 1, a molding compound 2, and a connecting wire assembly 3. The molding compound 2 is molded over the wound stator 1. The molding compound 2, the lower end cap 6, and the wound stator 1 are integrally injection molded.

[0036] Specifically, the wound stator 1 has multiple pins 11, and the encapsulation 2 has a stepped structure 21 for exposing the pins 11. The pins 11 exposed on the stepped structure 21 are used for electrical connection with the connecting wire assembly 3. An upper end cap 5 is connected to the upper end of the encapsulation 2. The upper end cap 5 is located near the pins 11, and there is a gap between the upper end cap 5 and the pins 11. An insulating gasket 4 is provided on the stepped structure 21, and the insulating gasket 4 is located between the upper end cap 5 and the connecting wire assembly 3. The connection direction between the upper end cap 5 and the lower end cap 6 is axial.

[0037] Specifically, the stepped structure 21 has a limiting portion 22 that protrudes radially inward. The connecting wire assembly 3 is arranged along the end face of the stepped structure 21 and connected to the pin 11. The limiting portion 22 is located outside the connecting wire assembly 3 and partially contacts the connecting wire assembly 3. Since the limiting portion 22 is between the connecting wire assembly 3 and the inner wall of the stator, the distance between the connecting wire assembly 3 and the inner wall of the stator is increased, thus preventing the connecting wire assembly 3 from contacting the inner wall of the stator.

[0038] Preferably, the connecting wire assembly 3 includes an electronic wire 31 electrically connected to the pin 11. A portion of the terminal 32 of the electronic wire 31 abuts against the limiting part 22, increasing the creepage distance between the terminal 32 and the upper end cover 5, thereby avoiding safety hazards caused by insufficient creepage distance of the motor. In addition, increasing the electrical clearance between the terminal 32 and the upper end cover 5 reduces the risk of poor motor withstand voltage. There is no need to add heat shrink tubing 35 to the terminal 32, which reduces the processing difficulty and cost of the connecting wire. Since there is no need to adjust the position of the terminal 32 during installation, the production efficiency of employees when installing the connecting wire is improved and the consistency of the product connecting wire line is guaranteed.

[0039] Preferably, the limiting part 22 includes a boss, which corresponds to and is located adjacent to the pin 11. By ensuring a one-to-one correspondence between the boss, pin 11, and terminal 32, the position of the terminal 32 does not need to be adjusted during installation, thus guaranteeing product consistency and improving production efficiency.

[0040] Specifically, the encapsulated body 2 is also provided with a wire exit clamp 33, and the electronic wire 31 extends from the pin 11 to the wire exit clamp 33 and passes through the wire exit clamp 33 within the stepped structure 21. The electronic wires 31 are bundled together by a sleeve 34.

[0041] In Embodiment Two, based on Embodiment One, preferably, the boss is semi-cylindrical in shape, and the radial width of the boss is greater than 10% of the axial distance between the terminal 32 and the upper end cover 5. The maximum width of the boss is not limited; it only needs to be such that the boss is not too wide and causes the electronic wire 31 to get tangled in the rotor. Preferably, the radial width of the boss is 1-2 mm.

[0042] If the boss width is too small, the creepage distance will be insufficient, and the motor will still be at risk of breakdown and short circuit. If the boss width is too large, there will be insufficient space for the electronic wire 31 to pass through, causing the electronic wire 31 to be too close to the inner side in the radial position and come into contact with the rotor. When the motor rotates, there is a risk that the electronic wire 31 will get caught in the rotor. When welding the terminal 32, the limited space and insufficient space for passing through will greatly increase the difficulty of welding and assembling the connecting wire assembly 3.

[0043] Specifically, in this embodiment, the boss has a height of 4.1 mm and a width of 1.5 mm, which satisfies the above requirements. The radial distance between the boss and the rotor is 9.7 mm, the maximum width of the three electronic lines 31 when they are parallel is 6 mm, and a minimum space of 3.7 mm is reserved.

[0044] Example 3 differs from Example 1 in that, as Figure 5 As shown, the connecting wire assembly 3 includes an electronic wire 31 electrically connected to the pin 11. The terminal 32 of the electronic wire 31 has a heat-shrinkable sleeve 35 on its outer side, and a portion of the heat-shrinkable sleeve 35 abuts against the limiting portion 22. In this embodiment, the heat-shrinkable sleeve 35 increases the insulation capability.

[0045] An electric motor includes a rotor and the aforementioned encapsulated stator.

[0046] In summary, the plastic-encapsulated stator and motor of this utility model increase the radial distance between the connecting wire assembly and the inner wall of the stator by limiting the connecting wire assembly radially through the limiting part, thus avoiding safety hazards caused by insufficient creepage distance.

[0047] The above description is based on the preferred embodiments of this utility model. Through the above description, those skilled in the art can make various changes and modifications without departing from the technical concept of this utility model. The technical scope of this utility model is not limited to the contents of the specification, but must be determined by the scope of the claims.

Claims

1. A plastic encapsulated stator, characterized by, include: A wound stator (1) having a plurality of pins (11); A plastic encapsulation body (2) is encapsulated on the outside of the wound stator (1) and has a stepped structure (21) for the pins (11) to be exposed, the stepped structure (21) having a limiting part (22) that protrudes radially inward; The connecting wire assembly (3) is arranged along the end face of the stepped structure (21) and connected to the pin (11), and the limiting part (22) is located outside the connecting wire assembly (3); The upper end cover (5) is placed on the end of the plastic seal (2) near the pin (11) and spaced apart from the pin (11) and the connecting wire assembly (3).

2. The plastic package stator according to claim 1, wherein The connecting wire assembly (3) includes an electronic wire (31) electrically connected to a pin (11) via a terminal (32), and the terminal (32) is correspondingly provided with a limiting part (22).

3. The plastic package stator according to claim 1, wherein The connecting wire assembly (3) includes an electronic wire (31) electrically connected to a pin (11) via a terminal (32), the terminal (32) having a heat-shrink tubing (35) on its outer side.

4. The plastic package stator according to claim 2 or 3, characterized by, The limiting part (22) includes a boss that abuts against a terminal (32) or a heat shrink tubing (35).

5. The plastic package stator according to claim 4, wherein The radial width of the boss is greater than 10% of the axial distance between the terminal (32) and the upper end cover (5).

6. The plastic package stator according to claim 4, wherein The radial width of the boss is 1-2 mm.

7. The encapsulated stator according to claim 4, characterized in that, The electronic wires (31) are bundled together by a sleeve (34).

8. The plastic package stator according to claim 7, wherein The encapsulated body (2) is also provided with a wire clip (33), and the electronic wire (31) extends from the pin (11) to the wire clip (33) and passes through the wire clip (33) within the stepped structure (21).

9. The plastic encapsulated stator of claim 8, wherein, An insulating pad (4) is provided on the stepped structure, and the insulating pad (4) is located between the upper end cover (5) and the connecting wire assembly (3).

10. The plastic encapsulated stator of claim 9, wherein, The boss and the encapsulation body (2) are integrally injection molded from BMC material.

11. An electric machine characterized by It includes a rotor and a plastic-encapsulated stator as described in any one of claims 1-10.

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