Stator structure and electric machine

Abstract

This utility model discloses a stator structure and a motor. The stator structure is used to install within a motor housing. The stator structure includes a stator core and a stator winding. The stator core is coaxially embedded within the motor housing, and its interior has a mounting portion extending axially along the motor housing. The stator winding is wound around the mounting portion and has an end winding protrusion protruding from the stator core. A thermally conductive filling layer is provided at the end of the stator core, surrounding the outer surface of the winding protrusion. The height L of the thermally conductive filling layer along the axial direction of the motor housing and the height L1 of the winding protrusion along the axial direction of the motor housing satisfy the relationship: 1.4L1≤L≤2L1. This utility model's stator structure and motor solve the problem that the height of the potting compound at both ends of the stator core in a motor, controlled manually based on experience, cannot guarantee optimal cost and performance.

Description

Technical Field

[0001] This utility model relates to the field of motor heat dissipation technology, and more specifically, to a stator structure and a motor. Background Technology

[0002] Currently, the stator windings in electric motors are primarily sealed with potting compound to improve their insulation and heat dissipation capabilities. The height of the potting compound relative to the stator core end is mainly controlled manually based on experience. However, the height of the potting compound has a significant impact on the motor. A higher height requires more potting compound, increasing both production costs and weight. A lower height fails to guarantee adequate heat dissipation, potentially leading to localized overheating and burnout of the stator windings, thus compromising the optimal balance between cost and performance. Utility Model Content

[0003] The main objective of this invention is to provide a stator structure and motor that can at least solve the problem that the height of the potting compound at both ends of the stator core in a motor cannot be controlled manually based on experience, thus failing to guarantee optimal cost and performance of the motor.

[0004] According to one aspect of the present invention, a stator structure is provided for mounting within a motor housing, the stator structure comprising:

[0005] A stator core, which is coaxially embedded in the motor housing, and the interior of the stator core has a mounting portion extending axially along the motor housing;

[0006] A stator winding is wound around the mounting portion. The stator winding has an end winding protrusion that protrudes from the stator core. A thermally conductive filling layer is provided at the end of the stator core. The thermally conductive filling layer surrounds the outer surface of the winding protrusion. The height L of the thermally conductive filling layer along the axial direction of the motor housing and the height L1 of the winding protrusion along the axial direction of the motor housing satisfy the relationship: 1.4L1≤L≤2L1.

[0007] Furthermore, the height L of the thermally conductive filling layer along the axial direction of the motor housing and the height L1 of the winding protrusion along the axial direction of the motor housing satisfy the following relationship: 1.6L1≤L≤1.7L1.

[0008] Furthermore, the distance Lmax between the end of the stator core and the end cover of the motor housing satisfies the relationship: Lmax > 2.5L1.

[0009] Furthermore, the angle θ between the top surface of the thermally conductive filling layer and the inner wall of the motor housing along the direction close to the stator core satisfies the relationship: 0 < θ < 90°.

[0010] Furthermore, the angle θ between the top surface of the thermally conductive filling layer and the inner wall of the motor housing along the direction close to the stator core satisfies the following relationship: 60°≤θ≤90°.

[0011] Furthermore, along the radial direction of the motor, the minimum distance between the thermally conductive filling layer and the inner wall of the motor housing is greater than the minimum distance between the thermally conductive filling layer and the inner wall of the stator core.

[0012] Furthermore, along the radial direction of the motor housing, the minimum distance S1 between the thermally conductive filling layer and the inner wall of the motor housing and the minimum distance S2 between the thermally conductive filling layer and the inner wall of the stator core satisfy the relationship: S1≥2S2.

[0013] Furthermore, the thermally conductive filling layer includes a thermally conductive silicone grease layer, a thermally conductive silicone layer, or a thermally conductive ceramic layer.

[0014] Furthermore, the outer periphery of the motor housing is provided with a plurality of cooling channels extending circumferentially along the motor housing, and coolant is disposed in the cooling channels.

[0015] On the other hand, the present invention also provides an electric motor, which includes the stator structure described above.

[0016] In this invention, by limiting the relationship between the height L of the thermally conductive filling layer along the axial direction of the motor housing and the height L1 of the winding protrusion to 1.4L1≤L≤2L1, it avoids insufficient coverage of the winding protrusion due to an excessively small L, ensuring that the heat generated by the stator winding can be fully transferred to the external heat dissipation structure through the thermally conductive filling layer, thus guaranteeing heat dissipation performance and preventing local high-temperature burnout. It also prevents waste of thermally conductive material due to an excessively large L. While controlling the motor production cost, it avoids excessively increasing the overall weight of the motor with the thermally conductive filling layer, thereby achieving the optimal balance between motor cost and performance while ensuring the reliability of stator winding heat dissipation. Attached Figure Description

[0017] The accompanying drawings, which are included to provide a further understanding of the present invention and constitute a part of this invention, illustrate exemplary embodiments of the present invention and, together with the description thereof, serve to explain the present invention and do not constitute an undue limitation thereof. In the drawings:

[0018] Figure 1 This is a partial cross-sectional view of the motor disclosed in an embodiment of the present utility model;

[0019] Figure 2 This is a partial cross-sectional view of the motor before glue application is completed, as disclosed in this embodiment of the utility model.

[0020] Figure 3This is a partial cross-sectional view of the motor disclosed in this embodiment of the present invention after glue application;

[0021] Figure 4 This is a schematic diagram of the temperature field of the motor windings under different thermal grease heights as disclosed in the embodiments of this utility model;

[0022] Figure 5 This is a graph showing the variation trend of the maximum temperature of the motor winding and the amount of thermal grease used with the height of the thermal grease, as disclosed in the embodiments of this utility model.

[0023] The above figures include the following reference numerals:

[0024] 10. Motor housing; 11. Cooling channel; 20. Stator core; 30. Stator winding; 31. Winding protrusion; 40. Thermally conductive filler layer. Detailed Implementation

[0025] It should be noted that, where there is no conflict, the embodiments and features in the embodiments of this utility model can be combined with each other. The present utility model will now be described in detail with reference to the accompanying drawings and embodiments.

[0026] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to the present invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0027] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps described in these embodiments do not limit the scope of this invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following drawings denote similar items; therefore, once an item is defined in one drawing, it need not be further discussed in subsequent drawings.

[0028] In related technologies, thermally conductive insulating materials are mainly used as the thermally conductive filling layer of motor windings to dissipate heat. In practical applications, the thermally conductive filling layer is mainly obtained by potting. However, there is no uniform standard for the potting height, which is determined entirely by manual experience. Too much potting increases the production cost of the motor, while too little potting leads to insufficient heat dissipation performance. Therefore, this application provides a stator structure and motor. This stator structure achieves low-cost shutdown and high heat dissipation performance by limiting the relationship between the height L of the thermally conductive filling layer along the axial direction of the motor housing and the height of the portion of the winding protruding from the end of the stator core. The shielding device of this utility model will be described in detail below with reference to the accompanying drawings.

[0029] See Figures 1 to 3 As shown, according to an embodiment of this application, a stator structure is provided for installation within a motor housing 10. The stator structure includes a stator core 20 and a stator winding 30. The stator core 20 is coaxially embedded within the motor housing 10, and the interior of the stator core 20 has a mounting portion extending axially along the motor housing 10. The stator winding 30 is wound around the mounting portion of the stator core 20. The stator winding 30 has an end winding protrusion 31 protruding from the stator core 20. A thermally conductive filling layer 40 is provided at the end of the stator core 20, surrounding the outer surface of the winding protrusion 31. The height L of the thermally conductive filling layer 40 along the axial direction of the motor housing 10 and the height L1 of the winding protrusion 31 along the axial direction of the motor housing 10 satisfy the relationship: 1.4L1≤L≤2L1.

[0030] Specifically, assuming the height L1 of the winding protrusion 31 along the axial direction of the motor housing 10 is 15mm, the height L of the heat-conducting filling layer 40 along the axial direction of the motor housing 10 satisfies the relationship: 21mm ≤ L ≤ 30mm. When L < 21mm, the heat dissipation effect of the motor is relatively poor. When L > 30mm, although the heat dissipation effect of the motor is greatly improved, the weight and cost of the motor are increased. By setting L within the range of 21mm to 30mm, not only can the heat dissipation performance of the motor be guaranteed, but the amount of heat-conducting filling layer 40 used can also be reduced to reduce the cost of the motor. For example, L can be set to 21mm, 22mm, 23mm, 24mm, 25mm, 26mm, 27mm, 28mm, 29mm, 30mm, etc.

[0031] Optionally, the thermally conductive filler layer 40 includes a thermally conductive silicone grease layer, a thermally conductive silicone layer, or a thermally conductive ceramic layer. The thermally conductive silicone grease layer has excellent flowability and filling properties, allowing it to tightly adhere to the tiny gaps between the stator core and the motor housing, significantly reducing interfacial thermal resistance and improving heat transfer efficiency. The thermally conductive silicone layer combines good thermal conductivity and elasticity, adapting to temperature changes and vibrations during motor operation, maintaining stable thermal contact over a long period, while also providing a certain degree of insulation protection. The thermally conductive ceramic layer has a high thermal conductivity and high-temperature resistance, enabling stable operation in high-temperature environments. It also exhibits strong chemical stability, preventing reactions with internal motor components, making it suitable for applications with high requirements for heat dissipation and reliability.

[0032] Before obtaining the relationship between L and L1 in this embodiment, a finite element analysis of the motor is required, referring to... Figure 2 As shown, the minimum height L of the thermally conductive filling layer 40 along the axial direction of the motor housing 10 is taken, and then increased sequentially from this minimum value. The final relationship for L is L = L + ΔL1 + ΔL2 + ΔL3 + ... + ΔLn. Thermally conductive silicone grease is used as the material for filling the thermally conductive filling layer 40, and the height L1 of the winding protrusion 31 along the axial direction of the motor housing 10 is set to 20mm. The thermal distribution of the motor under different height L values ​​(L does not exceed the distance Lmax between the end of the stator core 20 and the end cover of the motor housing 10) is analyzed, resulting in the following... Figure 4 The thermal distribution diagrams shown depict the thermal distribution of the motor when the height L of the thermally conductive filling layer 40 along the axial direction of the motor housing 10 is 0mm, 5mm, 10mm, 15mm, 20mm, 25mm, 30mm, 35mm, 40mm, 45mm, 50mm, and 55mm. The temperature gradually increases from blue to red in the diagrams. It can be seen that the higher temperature areas are mainly concentrated in the stator winding 30, and the temperature decreases further away from the stator winding 30. The temperature of the motor housing 10 is the lowest. Furthermore, the greater the height L of the thermally conductive filling layer 40 along the axial direction of the motor housing 10, the lower the temperature of the corresponding area, and the better the heat dissipation effect on the motor.

[0033] Based on the finite element analysis results, the following parameters are established: the height L of the thermally conductive filling layer 40 along the axial direction of the motor housing 10 (i.e., the height L of the thermally conductive grease), the highest temperature T of the stator winding 10 (in °C), and the amount of thermally conductive grease Q (in mm). 3 The fitting curve between ) is shown in the figure. Figure 5 As shown in the figure, the intersection point between the LT and LQ fitting curves corresponds to a thermal grease height of 25mm. This means that a thermal grease height of L of 25mm represents the optimal combination of motor temperature and thermal grease application. At this point, the highest stator winding temperature T is 142.5℃, and the thermal grease application amount Q is 4000mm. 3 .

[0034] Furthermore, the height L of the thermally conductive filler layer 40 along the axial direction of the motor housing 10 and the height L1 of the winding protrusion 31 along the axial direction of the motor housing 10 satisfy the relationship: 1.6L1≤L≤1.7L1. From the simulation results above, we can obtain 2.4mm≤L≤2.55mm, at which point the thermal grease height L is closer to the optimal value of 25mm. When L is less than 2.4mm, the motor's heat dissipation effect is relatively poor; when L is greater than 2.55mm, the motor cost is high. In practical applications, since it is impossible to guarantee that the thermal grease height L is accurately set to 25mm, the heat dissipation effect and the amount of thermal grease used are both optimal within the range of 2.4mm to 2.55mm, ensuring both effective heat dissipation and reduced motor cost. Therefore, in practical applications, any value within this range can be used.

[0035] Furthermore, the distance Lmax between the end of the stator core 20 and the end cover of the motor housing 10 satisfies the relationship: Lmax > 2.5L1. Given that the height L1 of the winding protrusion 31 along the axial direction of the motor housing 10 in the above embodiment is 20mm, we can obtain Lmax > 50mm. This means that the distance between the end of the stator core 20 and the end cover of the motor housing 10 needs to be greater than 50mm to ensure that the thermal grease has a certain adjustable range and to avoid the inability to obtain an optimal value due to the distance being too small.

[0036] like Figure 3 As shown, the angle θ between the top surface of the thermally conductive filling layer 40 and the inner wall of the motor housing 10 along the direction close to the stator core 20 satisfies the relationship: 0 < θ < 90°. That is, the top surface of the thermally conductive filling layer 40 and the inner wall of the motor housing 10 form a certain angle, meaning that the contact area between the thermally conductive filling layer 40 and the motor housing 10 is large. This allows the heat on the thermally conductive filling layer 40 to be quickly and massively transferred to the motor housing 10 for heat dissipation, which has the effect of increasing the heat dissipation capacity of the stator winding 30 while reducing the amount of thermal grease used.

[0037] Furthermore, the angle θ between the top surface of the thermally conductive filling layer 40 and the inner wall of the motor housing 10 along the direction near the stator core 20 satisfies the relationship: 60°≤θ≤90°. For example, θ can be set to 60°, 65°, 70°, 75°, 80°, 85°, 90°, etc. This ensures sufficient contact area between the thermally conductive filling layer 40 and the motor housing 10, ensuring efficient heat transfer from the thermally conductive filling layer 40 to the motor housing 10 and maintaining good heat dissipation. At the same time, it avoids excessive expansion of the thermally conductive filling layer 40 near the stator core 20 due to an excessively small θ, thus not occupying too much internal space of the motor, and better adapting to the layout of components such as the stator core 20 and stator winding 30, ensuring the compactness of the internal structure of the motor. The condition of 60°≤θ≤90° makes the inclination of the top surface of the thermally conductive filling layer 40 moderate, allowing heat transferred from the stator winding 30 to the thermally conductive filling layer 40 to diffuse more directly towards the motor housing 10. Compared to the case where θ < 60°, the heat transfer path is more directional, further improving the heat dissipation speed.

[0038] Furthermore, along the radial direction of the motor, the minimum distance between the thermally conductive filling layer 40 and the inner wall of the motor housing 10 is greater than the minimum distance between the thermally conductive filling layer 40 and the inner wall of the stator core 20. This provides a more reasonable diffusion space for heat transfer from the thermally conductive filling layer 40 to the motor housing 10, allowing for more thermally conductive filling layer 40 to be filled. The longer path of the thermally conductive filling layer 40 improves heat dissipation. Heat can be fully absorbed by the thermally conductive filling layer 40, preventing heat from concentrating on the motor housing 10 due to an insufficient minimum distance between the thermally conductive filling layer 40 and the inner wall of the motor housing 10.

[0039] Furthermore, along the radial direction of the motor housing 10, the minimum distance S1 between the thermally conductive filling layer 40 and the inner wall of the motor housing 10, and the minimum distance S2 between the thermally conductive filling layer 40 and the inner wall of the stator core 20, satisfy the relationship: S1≥2S2. Setting S1≥2S2 allows the thermally conductive filling layer 40 to be more abundant on the side closer to the motor housing 10, maximizing the absorption of heat generated by the stator core 20 and stator winding 30, and reducing the ineffective diffusion of heat to other non-heat dissipation areas inside the motor.

[0040] Furthermore, the outer periphery of the motor housing 10 is provided with several cooling channels 11 extending circumferentially along the motor housing 10, and coolant is disposed within the cooling channels 11. This enables the construction of a surrounding liquid cooling path on the outer periphery of the motor housing 10, allowing the heat transferred from the thermally conductive filling layer 40 to the motor housing 10 to be quickly carried away by the flowing coolant, significantly improving the heat dissipation efficiency of the motor housing 10. At the same time, the circumferentially extending channel layout can uniformly cover the outer periphery of the housing, ensuring that heat in all areas of the motor can be efficiently absorbed, avoiding local overheating. Combined with the heat transfer function of the internal thermally conductive filling layer 40, a synergistic heat dissipation system of internal heat conduction and external liquid cooling is formed, significantly enhancing the overall heat dissipation capacity of the motor, especially suitable for stable operation of motors in high-power, high-heat-generating scenarios.

[0041] On the other hand, this application also discloses an electric motor that includes the stator structure described above. Therefore, this electric motor incorporates all the technical effects of the aforementioned stator structure. Since the technical effects of the stator structure have already been described in detail above, they will not be repeated here.

[0042] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0043] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore cannot be construed as limiting the scope of protection of this utility model.

[0044] The above are merely preferred embodiments of this utility model and are not intended to limit the scope of this utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A stator structure for mounting within a motor housing (10), characterized in that, The stator structure includes: Stator core (20), the stator core (20) is coaxially embedded in the motor housing (10), and the interior of the stator core (20) has a mounting portion extending axially along the motor housing (10); A stator winding (30) is wound around the mounting portion. The stator winding (30) has an end winding protrusion (31) protruding from the stator core (20). A thermally conductive filling layer (40) is provided at the end of the stator core (20). The thermally conductive filling layer (40) surrounds the outer surface of the winding protrusion (31). The height L of the thermally conductive filling layer (40) along the axial direction of the motor housing (10) and the height L1 of the winding protrusion (31) along the axial direction of the motor housing (10) satisfy the relationship: 1.4L1≤L≤2L1.

2. The stator structure according to claim 1, characterized in that, The height L of the thermally conductive filling layer (40) along the axial direction of the motor housing (10) and the height L1 of the winding protrusion (31) along the axial direction of the motor housing (10) satisfy the following relationship: 1.6L1≤L≤1.7L1.

3. The stator structure according to claim 1 or 2, characterized in that, The distance Lmax between the end of the stator core (20) and the end cover of the motor housing (10) satisfies the relationship: Lmax > 2.5L1.

4. The stator structure according to claim 1, characterized in that, The angle θ between the top surface of the thermally conductive filling layer (40) and the inner wall of the motor housing (10) along the direction close to the stator core (20) satisfies the following relationship: 0 < θ < 90°.

5. The stator structure according to claim 4, characterized in that, The angle θ between the top surface of the thermally conductive filling layer (40) and the inner wall of the motor housing (10) along the direction close to the stator core (20) satisfies the following relationship: 60°≤θ≤90°.

6. The stator structure according to claim 1, characterized in that, Along the radial direction of the motor, the minimum distance between the thermally conductive filling layer (40) and the inner wall of the motor housing (10) is greater than the minimum distance between the thermally conductive filling layer (40) and the inner wall of the stator core (20).

7. The stator structure of claim 6, wherein Along the radial direction of the motor housing (10), the minimum distance S1 between the thermally conductive filling layer (40) and the inner wall of the motor housing (10) and the minimum distance S2 between the thermally conductive filling layer (40) and the inner wall of the stator core (20) satisfy the following relationship: S1≥2S2.

8. The stator structure according to any one of claims 1 to 7, characterized in that, The thermally conductive filler layer (40) includes a thermally conductive grease layer, a thermally conductive silicone layer, or a thermally conductive ceramic layer.

9. The stator structure according to any one of claims 1 to 7, characterized in that, The outer periphery of the motor housing (10) is provided with a plurality of cooling channels (11) extending circumferentially along the motor housing (10), and coolant is provided in the cooling channels (11).

10. An electric motor, characterized in that, Includes the stator structure as described in any one of claims 1 to 9.

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