Stator and electric machine

Abstract

The application relates to the motor technical field and provides a stator and a motor. The stator comprises a stator core, a first insulation part and a winding. The first insulation part is arranged on the surface of the inner wall of the stator slot, can cover the defects such as burrs on the inner wall of the stator slot, and prevents the defects on the inner wall of the stator slot from damaging the winding. The first insulation part can also insulate and separate the first wire part of the wire in the winding from the stator core, so that the wire is electrically connected with the stator core. The first wire part of the wire of the winding is located in the stator slot and is not covered by the second insulation part, so that the second insulation part does not additionally occupy the space in the stator slot, thereby making the cross-sectional area of the first wire part in the axial direction of the stator core larger and the heat dissipation path between the stator core and the first wire part shorter. In addition, the volume of the wire arranged in the stator slot is larger, the filling rate of the wire in the stator slot is effectively improved after the winding is arranged in the stator slot, and the electrical performance of the stator is better.

Description

[0001] This disclosure claims priority to Chinese Patent Application No. 202520455239.1, filed on March 14, 2025, entitled “Stator Structure and Motor”, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This application relates to a stator and motor, belonging to the field of electrical technology. Background Technology

[0003] An electric motor consists of a stator and a rotor. The stator mainly comprises a stator core and windings. The stator core is a key magnetic circuit component in the motor that enables electromagnetic energy conversion, and its structural design directly affects the motor's efficiency, power density, and temperature rise performance. During operation, the motor generates a significant amount of heat, leading to excessively high winding temperatures.

[0004] Currently, when motor windings are installed in stator slots within the stator core, insulating varnish needs to be applied to the surface of the windings to ensure insulation between the windings and the stator core. This results in an increase in the outer diameter of the conductors in the windings, leading to a relatively small conductor volume within the stator slots, which limits further improvements in motor power density. Utility Model Content

[0005] This application provides a stator and a motor to solve the problem of excessively high motor temperature in related technologies.

[0006] To achieve the above objectives, this application adopts the following technical solution:

[0007] In a first aspect, this application provides a stator comprising:

[0008] A stator core having stator slots that extend through the stator core along its axial direction;

[0009] A first insulating part is disposed in the stator slot, and the first insulating part covers the inner wall of the stator slot;

[0010] The winding includes multiple conductors and a second insulating portion. The multiple conductors are all inserted into the stator slot. Each conductor includes a first wire portion and a second wire portion connected to each other. The first wire portion is located inside the stator slot, and the second wire portion is located outside the stator slot. The second insulating portion covers the surface of the second wire portion.

[0011] In some embodiments, the stator further includes a third insulating portion, through which the first wire portion is connected to both the first insulating portion and the third insulating portion.

[0012] In some embodiments, the third insulating portion fills the gap between the first wire portion and the first insulating portion.

[0013] In some embodiments, the first wire portions of the plurality of wires are spaced apart, and the third insulating portion fills the gap between the first wire portions of adjacent wires.

[0014] In some embodiments, both the first insulating portion and the third insulating portion are thermal fasteners.

[0015] In some embodiments, the first insulating portion includes epoxy resin, unsaturated polyester resin, phenolic resin, polyphenylene sulfide, polyether ether ketone, polytetrafluoroethylene, or fusible polytetrafluoroethylene.

[0016] The third insulating part includes epoxy resin, unsaturated polyester resin, phenolic resin, polyphenylene sulfide, polyether ether ketone, polytetrafluoroethylene or fusible polytetrafluoroethylene.

[0017] In some embodiments, the conductor includes a first segment and a second segment, the two ends of the first segment being opposite to and connected to the two ends of the second segment, and the connection point between the first segment and the second segment being located within the stator slot.

[0018] In some implementations, the two ends of the first line segment are welded to the two ends of the second line segment.

[0019] In some embodiments, the second insulating portion comprises epoxy resin or polyurethane.

[0020] Secondly, based on the stator described above, this application also proposes an electric motor that includes the stator described above.

[0021] In the stator provided in this application, the first insulating portion is disposed on the surface of the inner wall of the stator slot, which can cover burrs and other defects on the inner wall of the stator slot to prevent damage to the winding. The first insulating portion can also insulate and separate the first wire portion of the winding conductor from the stator core, resulting in electrical connection between the conductor and the stator core. The first wire portion of the winding conductor is located in the stator slot and is not covered by the second insulating portion, so the second insulating portion does not occupy additional space in the stator slot. This results in a larger cross-sectional area of ​​the first wire portion in the axial direction of the stator core, and a shorter heat dissipation path between the stator core and the first wire portion. In addition, the conductor passing through the stator slot has a larger volume, which effectively improves the conductor filling rate in the stator slot after the winding passes through the stator slot, resulting in better electrical performance of the stator of this application. This helps to improve the torque capacity and power density of the motor.

[0022] The motor provided in this application includes the stator described above, which helps to improve the motor's torque capability and increase its power density. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 A schematic diagram of the stator provided in the embodiments of this application;

[0025] Figure 2 A schematic diagram of the first line portion of the stator provided in an embodiment of this application;

[0026] Figure 3 A schematic diagram of the stator windings provided in an embodiment of this application;

[0027] Figure 4 A schematic diagram of a stator core provided in an embodiment of this application;

[0028] Figure 5 A schematic diagram showing the connection between the stator core and the first insulation portion provided in an embodiment of this application;

[0029] Figure 6 A schematic diagram of the conductor of the stator core provided in the embodiments of this application;

[0030] Figure 7 Schematic diagram of the third insulating part of the stator provided in the embodiments of this application Figure 1 ;

[0031] Figure 8 Schematic diagram of the third insulating part of the stator provided in the embodiments of this application Figure 2 .

[0032] Explanation of reference numerals in the attached figures:

[0033] 100 - Stator core; 110 - Stator slot;

[0034] 200 - First insulation part; 210 - Mounting slot;

[0035] 300 - Winding; 310 - Conductor; 311 - First wire section; 312 - Second wire section; 313 - First wire segment; 314 - Second wire segment; 315 - Metallic dielectric; 320 - Second insulation section;

[0036] 400 - Third Insulation Section. Detailed Implementation

[0037] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0038] An electric motor consists of a stator and a rotor. The stator mainly comprises a stator core and windings. The stator core is a key magnetic circuit component in the motor that enables electromagnetic energy conversion, and its structural design directly affects the motor's efficiency, power density, and temperature rise performance. During operation, the motor generates a significant amount of heat, leading to excessively high winding temperatures.

[0039] Currently, when motor windings are installed in stator slots within the stator core, insulating varnish needs to be applied to the surface of the windings to ensure insulation between the windings and the stator core. This results in an increase in the outer diameter of the conductors in the windings, leading to a relatively small conductor volume within the stator slots, which limits further improvements in motor power density.

[0040] In the stator proposed in this application, the first insulating portion is disposed on the surface of the inner wall of the stator slot, which can cover burrs and other defects on the inner wall of the stator slot to prevent damage to the winding. The first insulating portion can also insulate and separate the first wire portion of the winding conductor from the stator core, resulting in electrical connection between the conductor and the stator core. The first wire portion of the winding conductor is located in the stator slot and is not covered by the second insulating portion, so the second insulating portion does not occupy additional space in the stator slot. This allows the first wire portion to have a larger cross-sectional area in the axial direction of the stator core, shortening the heat dissipation path between the stator core and the first wire portion. In addition, the conductor passing through the stator slot has a larger volume, effectively increasing the conductor filling rate in the stator slot after the winding passes through the stator slot, resulting in better electrical performance of the stator of this application. This helps to improve the torque capacity and power density of the motor.

[0041] The motor proposed in this application includes the stator described above, which helps to improve the motor's torque capability and increase its power density.

[0042] The contents of this application will now be described in detail with reference to the accompanying drawings, so that those skilled in the art can have a clearer and more detailed understanding of the contents of this application.

[0043] This application proposes a stator, with reference to Figures 1 to 5 As shown, it includes a stator core 100, a first insulation portion 200, and a winding 300. This stator can be used in an electric motor.

[0044] The stator core 100 is the basic component of the stator in this application, and it can provide a mounting base for at least some other components of the stator. The stator core 100 can be a ring-shaped structure with through holes for mounting the motor rotor. The stator core 100 may have stator slots 110, which extend through the stator core 100 along its axial direction, such that both ends of the slots form openings on the axial end faces of the stator core 100. Multiple stator slots 110 can be provided, spaced apart circumferentially along the stator core 100. The axial direction of the stator core 100 is... Figure 3 In the Y direction, the radial direction of the stator core 100 is... Figure 3 The X direction in the equation.

[0045] The first insulating part 200 is disposed within the stator slot 110 of the stator core 100, and the first insulating part 200 covers the inner wall of the stator slot 110. It should be understood that the stator core 100 is affected by the processing technology, and the inner wall of the stator slot 110 may have defects such as burrs. By covering the inner wall of the stator slot 110 with the first insulating part 200, the first insulating part 200 can cover the burrs and other defects on the inner wall of the stator slot 110.

[0046] The winding 300 passes through the stator slot 110 of the stator core 100. The winding 300 can be connected to an external circuit to conduct electricity. The stator core 100 provides a low magnetic reluctance path for the magnetic field, efficiently guiding the magnetic flux generated by the current in the winding 300 into the air gap between the stator core 100 and the rotor, thus interacting with the rotor. The winding 300 includes multiple conductors 310 and a second insulation portion 320. All conductors 310 pass through the inner wall of the stator slot 110. The conductors 310 are radially distributed along the stator core 100. Gaps exist between adjacent conductors 310 to separate them and prevent short circuits caused by contact.

[0047] Specifically, the conductor 310 includes a first wire portion 311 and a second wire portion 312. The first wire portion 311 is connected to the second wire portion 312. The first wire portion 311 is located inside the stator slot 110 of the stator core 100, and the second wire portion 312 is located outside the stator slot 110. The second insulating portion 320 covers the second wire portion 312 of the conductor 310, so that the second wire portions 312 of multiple conductors 310 can be insulated and separated.

[0048] The first wire portion 311 is located within the stator slot 110, and is not covered by the second insulating portion 320, thus the second insulating portion 320 does not occupy additional space within the stator slot 110. Consequently, the space available for the first wire portion 311 within the stator slot 110 is larger, resulting in a larger cross-sectional area of ​​the first wire portion 311 along the axial direction of the stator core 100. This leads to a larger volume of the conductor 310 passing through the stator slot 110. After the winding 300 passes through the stator slot 110, the filling rate of the conductor 310 within the stator slot 110 is effectively improved, resulting in better electrical performance of the stator of this application. This helps to improve the torque capability of the motor using the stator of this application and increase the power density of the motor.

[0049] Furthermore, the distance between the first wire portion 311 and the inner wall of the stator slot 110 is also smaller, which shortens the heat dissipation path between the first wire portion 311 and the stator core 100. After the wire 310 generates heat when energized, the heat can be conducted to the stator core 100 more efficiently, resulting in a lower temperature of the wire 310, thereby making the stator operation of this application safer and more stable.

[0050] The first insulating part 200 is located between the winding 300 and the inner wall of the stator slot 110. The first insulating part 200 can separate the first wire part 311 of the conductor 310 from the inner wall of the stator slot 110, so that the first wire part 311 will not come into contact with the stator core 100, thus preventing the winding 300 from short-circuiting.

[0051] In some embodiments, as shown in the figures, in order for the first insulating portion 200 to adequately insulate and separate the winding 300 from the stator core 100, the first insulating portion 200 may be arranged circumferentially along the stator slot 110. In this way, the first insulating portion 200 can cover the inner wall of the stator slot 110 to prevent the winding 300 in the stator slot 110 from contacting the stator core 100.

[0052] Specifically, the shape of the first insulating part 200 can match the slot shape of the stator slot 110 of the stator core 100. The first insulating part 200 has a mounting slot 210, in which the winding 300 can be disposed. In this way, the portion of the winding 300 located in the stator slot 110 is opposite to the first insulating part 200 on all sides, so that the first insulating part 200 can fully separate the winding 300 from the stator core 100.

[0053] The outer wall of the first insulating part 200 is fitted to the inner wall of the stator slot 110 of the stator core 100, allowing the first insulating part 200 to have a closer contact with the stator core 100. This reduces the space occupied by the first insulating part 200 within the stator slot 110, allowing for a larger mounting slot 210 that can accommodate a larger winding 300. This results in better stator performance in this application.

[0054] In some implementations, reference Figures 6 to 7 As shown, in order to connect and fix the winding 300 of this application to the first insulating part 200, the stator of this application may also include a third insulating part 400. The third insulating part 400 is disposed in the mounting groove 210 of the first insulating part 200, and the third insulating part 400 is located between the winding 300 and the first insulating part 200, so that the winding 300 can be fixed to the first insulating part 200 through the third insulating part 400.

[0055] Specifically, a certain gap can be provided between the winding 300 and the first insulating part 200, which allows the third insulating part 400 to be provided. The third insulating part 400 is connected to both the winding 300 and the first insulating part 200, thereby fixing the winding 300 to the first insulating part 200. By fixing the winding 300 to the first insulating part 200 through the third insulating part 400, it is unnecessary to provide a complex fixing structure on the first insulating part 200 or the winding 300, making the fixing method of the winding 300 to the first insulating part 200 simple, thereby reducing the manufacturing cost of the stator of this application.

[0056] In some embodiments, to facilitate the placement of the third insulating portion 400 between the winding 300 and the first insulating portion 200 for fixing the winding 300 and the first insulating portion 200, the third insulating portion 400 can be a thermosetting fastener. Specifically, the third insulating portion 400 can be heat-formed into a fluid state, which fills the gap between the winding 300 and the first insulating portion 200. By further heating the fluid third insulating portion 400, it can be thermoset between the first wire portion 311 and the first insulating portion 200, thereby fixing the first wire portion 311 within the stator slot 110. Correspondingly, the winding 300 as a whole can be fixed to the stator core 100.

[0057] In manufacturing the stator of this application, multiple wires 310 from the winding 300 can be first threaded into the mounting groove 210 of the first insulating part 200, with gaps between the first wire portions 311 of the multiple wires 310. There is also a gap between the wires 310 and the first insulating part 200, and the cooling channels for the flow of cooling liquid in the gap between the wires 310 and the first insulating part 200 can be filled with a removable filler. Subsequently, the third insulating part 400 in a fused state can be filled into the mounting groove 210 of the first insulating part 200. Under the action of gravity, the third insulating part 400 in a fused state can fill the gap between the wires 310 and the first insulating part 200, thus fixing the wires 310 to the first insulating part 200. After the third insulating part 400 in the hot-melt state solidifies, the filler between the wire 310 and the first insulating part 200 can be removed, so that the wire 310 and the first insulating part 200 are fixedly connected, and a gap is formed between the wire 310 and the first insulating part 200 to form a cooling channel.

[0058] Furthermore, due to the fluidity of the third insulating part 400 in the heat-fused state, the third insulating part 400 in the heat-fused state can fully fill the gap between the wire 310 and the first insulating part 200, making the connection between the wire 310 and the first insulating part 200 more stable and reliable.

[0059] In some embodiments, the third insulating portion 400 in this application may be made of epoxy resin, unsaturated polyester resin, phenolic resin, polyphenylene sulfide, polyetheretherketone, polytetrafluoroethylene, or fusible polytetrafluoroethylene. The third insulating portion 400 may also be a mixture of at least two of epoxy resin, unsaturated polyester resin, phenolic resin, polyphenylene sulfide, polyetheretherketone, polytetrafluoroethylene, or fusible polytetrafluoroethylene. Epoxy resin, unsaturated polyester resin, phenolic resin, polyphenylene sulfide, polyetheretherketone, polytetrafluoroethylene, or fusible polytetrafluoroethylene can all be cured by thermosetting to connect the first wire portion 311 to the first insulating portion 200.

[0060] In some embodiments, the first insulating part 200 of this application may also be a thermosetting casting, so that the first insulating part 200 can be formed by thermosetting, thus making the connection between the first insulating part 200 and the stator core 100 more stable and reliable.

[0061] Specifically, in the fabrication of the stator of this application, a heated, fluidized first insulating portion 200 can be disposed within the stator slot 110 of the stator core 100, and the fluidized first insulating portion 200 can be further heated to fix it within the stator slot 110 of the stator core 100. The first insulating portion 200 is thermosetting within the stator slot 110 of the stator core 100, allowing it to fully match the slot shape of the stator slot 110. This enables the first insulating portion 200 to better cover the inner wall of the stator slot 110, thus effectively separating the winding 300 from the stator core 100.

[0062] In some embodiments, the first insulating portion 200 in this application may be made of epoxy resin, unsaturated polyester resin, phenolic resin, polyphenylene sulfide, polyetheretherketone, polytetrafluoroethylene, or fusible polytetrafluoroethylene. The first insulating portion 200 may also be a mixture of at least two of epoxy resin, unsaturated polyester resin, phenolic resin, polyphenylene sulfide, polyetheretherketone, polytetrafluoroethylene, or fusible polytetrafluoroethylene. Epoxy resin, unsaturated polyester resin, phenolic resin, polyphenylene sulfide, polyetheretherketone, polytetrafluoroethylene, or fusible polytetrafluoroethylene can all be cured by thermosetting to cover the burrs on the inner wall of the stator groove 110.

[0063] When the height of the burr is 0.3 mm, the thickness of the first insulating portion 200 can be 0.3 mm or 0.4 mm. The thickness of the first insulating portion 200 needs to be no less than the height of the burr to avoid the surface of the first wire portion 311 being scratched by the burr.

[0064] In some embodiments, the first insulating portion 200 is flush with both sides of the stator core 100 along the axial direction of the stator core 100. This prevents the first insulating portion 200 from protruding from the surface of the stator core 100, resulting in a smoother surface for the stator of this application. Furthermore, the amount of the first insulating portion 200 can be reduced, making the structure of the stator of this application more compact.

[0065] In some implementations, reference Figure 8As shown, the conductor 310 of this application may further include a first segment 313 and a second segment 314, with the two ends of the first segment 313 respectively facing and connected to the two ends of the second segment 314. Specifically, the conductor 310 has a ring structure, with the two ends of the first segment 313 respectively connecting to the two ends of the second segment 312. When assembling the stator of this application, the first segment 313 can be inserted into the stator slot 110 through one side opening of the stator slot 110 of the stator core 100, and the second segment 314 can be inserted into the stator slot 110 through the other side opening of the stator slot 110 of the stator core 100, so that the two ends of the first segment 313 are respectively connected to the two ends of the second segment 314, and the connection between the first segment 313 and the second segment 314 is located within the stator slot 110.

[0066] In some implementations, the two ends of the first segment 313 and the two ends of the second segment 314 can be connected by welding, so that the electrical connection between the first segment 313 and the second segment 314 is stable and reliable, and the overall structure of the conductor 310 is stable and reliable, and ultimately the structure of the winding 300 is stable and reliable.

[0067] To ensure the reliability and conductivity of the welding, the first segment 313 and the second segment 314 can be connected by a metal medium 315. For example, the first segment 313 and the second segment 314 can be connected by materials with good electrical and thermal conductivity, such as silver, copper, or brazing.

[0068] Based on the stator described above, this application also proposes an electric motor that includes the stator described above. Furthermore, the electric motor may also include a rotor, which is movably disposed within a through-hole in the stator core 100.

[0069] It should be noted that the terms "one embodiment," "embodiment," "exemplary embodiment," "some embodiments," etc., mentioned in the specification indicate that the described embodiment may include a specific feature, structure, or characteristic, but not every embodiment necessarily includes that specific feature, structure, or characteristic. Furthermore, such phrases do not necessarily refer to the same embodiment. Moreover, when a specific feature, structure, or characteristic is described in connection with an embodiment, implementing such a feature, structure, or characteristic in conjunction with other embodiments, whether explicitly described or not, is within the knowledge scope of those skilled in the art.

[0070] Generally speaking, terms should be understood at least in part by their use in context. For example, at least in part by context, the term "one or more" as used in the text can be used to describe any feature, structure, or characteristic of the singular meaning, or a combination of features, structures, or characteristics of the plural meaning. Similarly, at least in part by context, terms such as "a" or "the" can also be understood to convey either singular or plural usage.

[0071] It should be readily understood that the terms “on,” “above,” and “on top of” in this application should be interpreted in the broadest possible sense, such that “on” means not only “directly on something” but also “on something” with an intermediate feature or layer therebetween, and that “above” or “on top of” means not only “on something” but also “on something” without an intermediate feature or layer therebetween (i.e., directly on something).

[0072] Furthermore, for ease of explanation, spatially relative terms such as "below," "below," "under," "above," and "above" may be used to describe the relationship of one element or feature relative to other elements or features as shown in the figures. Spatially relative terms are intended to encompass different orientations of the device in use or operation other than those shown in the figures. The device may have other orientations (rotated 90° or in other orientations), and the spatially relative descriptive terms used herein may be interpreted accordingly.

[0073] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A stator, characterized in that, include: The stator core (100) has a stator slot (110) that extends through the stator core (100) along its axial direction. A first insulating part (200) is disposed in the stator slot (110), and the first insulating part (200) covers the inner wall of the stator slot (110); The winding (300) includes multiple conductors (310) and a second insulation portion (320). The multiple conductors (310) are all inserted into the stator slot (110). Each conductor (310) includes a first wire portion (311) and a second wire portion (312) connected to each other. The first wire portion (311) is located inside the stator slot (110), and the second wire portion (312) is located outside the stator slot (110). The second insulation portion (320) covers the surface of the second wire portion (312).

2. The stator according to claim 1, characterized in that, The stator further includes a third insulating part (400), through which the first wire part (311) is connected to the first insulating part (200).

3. The stator according to claim 2, characterized in that, The third insulating portion (400) fills the gap between the first wire portion (311) and the first insulating portion (200).

4. The stator according to claim 3, characterized in that, The first wire portions (311) of the plurality of wires (310) are spaced apart, and the third insulating portion (400) fills the gap between the first wire portions (311) of adjacent wires (310).

5. The stator according to claim 2, characterized in that, Both the first insulating part (200) and the third insulating part (400) are thermal fasteners.

6. The stator according to claim 5, characterized in that, The first insulating part (200) includes epoxy resin, unsaturated polyester resin, phenolic resin, polyphenylene sulfide, polyether ether ketone, polytetrafluoroethylene or fusible polytetrafluoroethylene; The third insulating part (400) includes epoxy resin, unsaturated polyester resin, phenolic resin, polyphenylene sulfide, polyether ether ketone, polytetrafluoroethylene or fusible polytetrafluoroethylene.

7. The stator according to any one of claims 1-6, characterized in that, The conductor (310) includes a first segment (313) and a second segment (314). The two ends of the first segment (313) are opposite to and connected to the two ends of the second segment (314). The connection between the first segment (313) and the second segment (314) is located in the stator slot (110).

8. The stator according to claim 7, characterized in that, The two ends of the first line segment (313) are welded to the two ends of the second line segment (314).

9. The stator according to any one of claims 1-6, characterized in that, The second insulating part (320) comprises epoxy resin or polyurethane.

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

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