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, an insulation piece and a winding. A first insulation part in the insulation piece is located between the winding and the inner wall of a stator slot, the first insulation part can separate the winding from the stator core, and the winding and the stator core are prevented from being in contact and short-circuited. The winding is arranged in the stator slot of the stator core, part of the winding is located outside the stator slot, and a second insulation part can insulate and separate the part of the winding located outside the stator slot from the stator core. The second insulation part is arranged at an angle with the first insulation part, and the first insulation part and the second insulation part are an integral structure, so that the second insulation part does not extend along the axial direction of the stator slot completely, and correspondingly, the size of the second insulation part in the axial direction of the stator slot is smaller under the condition that the surface length of the second insulation part is constant. Therefore, the length of the winding in the axial direction of the stator slot can be reduced, the structure of the stator is more compact, the cost is lower, and the heat generation amount can be reduced.

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. A safe creepage distance needs to be maintained between the windings and the stator core to ensure the safe and stable operation of the stator motor.

[0004] Currently, the creepage distance between the windings and the stator core is increased by placing insulating paper between the stator core and the windings. Consequently, the winding length also needs to be set larger, resulting in an increase in the height of the motor end, an increase in volume, an increase in cost, and an increase in heat generation. Utility Model Content

[0005] This application provides a stator to solve the problem of excessive heat generation in motors 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 a stator slot extending through the stator core along its axial direction;

[0009] An insulating component includes multiple integrally connected first insulating portions and second insulating portions. The first insulating portions are disposed within the stator slot, and the second insulating portions are located outside the stator slot, with the second insulating portions and the first insulating portions arranged at an angle.

[0010] The winding passes through the stator slot, and the first insulating part is located between the inner wall of the stator slot and the winding.

[0011] In some embodiments, the first insulating portion is arranged circumferentially along the stator slot, the outer wall of the insulating member is in contact with the inner wall of the stator slot, the first insulating portion has a mounting slot, and the winding passes through the mounting slot.

[0012] In some embodiments, the second insulating portion is connected to the side of the first insulating portion adjacent to the center of the stator core.

[0013] In some embodiments, there are two second insulating portions, which are connected to the two ends of the first insulating portion along the axial direction of the stator core.

[0014] In some embodiments, the second insulating portion is fitted to the axial end face of the stator core.

[0015] In some embodiments, the first insulating portion has a first thickness on one side of the stator core adjacent to the center of the stator core along the radial direction of the stator core, and the second insulating portion has a second thickness along the axial direction of the stator core, wherein the first thickness is less than the second thickness.

[0016] In some embodiments, the first insulating portion has a third thickness on the side adjacent to the edge of the stator core along the radial direction of the stator core, the third thickness being greater than the first thickness.

[0017] In some embodiments, along the axial direction of the stator core, both ends of the first insulating portion are flush with the axial end face of the stator core.

[0018] In some embodiments, the insulating component is a thermosetting injection molded structural component, and the insulating component is an integral structural component.

[0019] Secondly, based on the stator described above, this application also proposes an electric motor that includes the stator described above.

[0020] The stator provided in this application has a first insulating portion located between the winding and the inner wall of the stator slot. This first insulating portion separates the winding from the stator core, preventing short circuits caused by contact between the winding and the stator core. The winding passes through the stator slot of the stator core, with a portion of the winding located outside the stator slot. A second insulating portion insulates and separates the portion of the winding outside the stator slot from the stator core. The second insulating portion is angled to the first insulating portion, preventing it from extending completely along the axial direction of the stator slot. Consequently, with a fixed surface length, the axial dimension of the second insulating portion in the stator slot is smaller. This allows for a smaller axial dimension of the winding in the stator slot, and also provides a safe creepage distance between the winding and the stator. Therefore, the axial length of the winding in the stator slot can be reduced, resulting in a more compact stator structure, lower cost, and reduced heat generation. The first insulating part and the second insulating part can be manufactured by an integral forming process, so that the first insulating part and the second insulating part are an integral structure. In this way, the first insulating part and the second insulating part do not need to be connected separately, and the connection between the first insulating part and the second insulating part is more stable and reliable. Correspondingly, the structure of the insulating part is more stable and reliable, which improves the structural stability of the stator and reduces the difficulty and cost of the manufacturing process.

[0021] The motor provided in this application, including the stator mentioned above, allows for a more compact and stable structure, less heat generation, and lower cost. Attached Figure Description

[0022] 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.

[0023] Figure 1 A schematic diagram of the stator provided in the embodiments of this application;

[0024] Figure 2 A schematic diagram of the stator insulation component provided in an embodiment of this application;

[0025] Figure 3 This is a partial schematic diagram of the stator insulation component provided in an embodiment of this application;

[0026] Figure 4 This is a schematic diagram of the first and second insulating portions of the stator provided in an embodiment of this application.

[0027] Explanation of reference numerals in the attached figures:

[0028] 100 - Stator core; 110 - Stator slot;

[0029] 200 - Insulating component; 210 - First insulating part; 211 - Mounting groove; 220 - Second insulating part;

[0030] 300 - Winding; 310 - Conductor. Detailed Implementation

[0031] 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.

[0032] 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. A safe creepage distance needs to be maintained between the windings and the stator core to ensure the safe and stable operation of the stator motor.

[0033] Currently, the creepage distance between the windings and the stator core is increased by placing insulating paper between the stator core and the windings. Consequently, the winding length also needs to be set to be larger, resulting in greater heat generation in the motor, increased height at the motor end, increased volume, increased cost, and increased heat generation.

[0034] The stator proposed in this application has a first insulating portion located between the winding and the inner wall of the stator slot. This first insulating portion separates the winding from the stator core, preventing short circuits caused by contact between the winding and the stator core. The winding passes through the stator slot of the stator core, with a portion of the winding located outside the stator slot. A second insulating portion insulates and separates the portion of the winding outside the stator slot from the stator core. The second insulating portion is angled to the first insulating portion, preventing it from extending completely along the axial direction of the stator slot. Consequently, with a fixed surface length, the axial dimension of the second insulating portion in the stator slot is smaller. This allows for a smaller axial dimension of the winding in the stator slot, and also provides a safe creepage distance between the winding and the stator. Therefore, the axial length of the winding in the stator slot can be reduced, resulting in a more compact stator structure, lower cost, and reduced heat generation. The first insulating part and the second insulating part can be manufactured by an integral forming process, so that the first insulating part and the second insulating part are an integral structure. In this way, the first insulating part and the second insulating part do not need to be connected separately, and the connection between the first insulating part and the second insulating part is more stable and reliable. Correspondingly, the structure of the insulating part is more stable and reliable, which improves the structural stability of the stator and reduces the difficulty and cost of the manufacturing process.

[0035] The motor proposed in this application, including the stator mentioned above, allows for a more compact and stable structure, generates less heat, and has a lower cost.

[0036] 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.

[0037] This application proposes a stator, with reference to Figures 1 to 4 As shown, it includes a stator core 100, an insulator 200, and a winding 300. This stator can be used in an electric motor.

[0038] 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 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 4 In the X direction, the circumferential direction of the stator core is... Figure 4 in the Y direction.

[0039] An insulating component 200 is disposed within the stator slot 110 of the stator core 100, and a winding 300 is also disposed within the stator slot 110 of the stator core 100. The winding 300 can be connected to an external circuit for energization. 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, allowing interaction with the rotor. The winding 300 is connected to the insulating component 200, allowing it to be fixed within the stator slot 110 of the stator core 100. The insulating component 200 is located between the winding 300 and the inner wall of the stator slot 110, separating the winding 300 from the inner wall of the stator slot 110 and preventing the winding 300 from contacting the stator core 100, thus preventing short circuits.

[0040] Specifically, the winding 300 passes through the stator slot 110 of the stator core 100, such that part of the winding 300 is located inside the stator slot 110, and the other part of the winding 300 is located outside the stator slot 110. The insulating member 200 includes a first insulating part 210 and a second insulating part 220 connected to each other. The first insulating part 210 is located inside the stator slot 110 of the stator core 100, and the second insulating part 220 is located outside the stator slot 110 of the stator core 100. The first insulating part 210 is located between the winding 300 and the inner wall of the stator slot 110, so that the first insulating part 210 can separate the winding 300 from the inner wall of the stator slot 110, preventing the winding 300 from directly contacting the inner wall of the stator slot 110 and short-circuiting. The second insulating part 220 is located outside the stator slot 110, and the second insulating part 220 is located between the outer wall of the stator core 100 and the winding 300.

[0041] It should be understood that creepage distance refers to the shortest path length along the insulating surface between two conductive components with a high voltage difference, and is a key indicator for measuring insulation performance. The winding 300 and the stator core 100 are two conductive components, and the shortest path length along the surface of the insulating component 200 for the winding 300 and the stator core 100 is their creepage distance. Therefore, the current between the winding 300 and the stator core 100 must bypass the second insulating part 220 to be transmitted between them.

[0042] The second insulating portion 220 is set at an angle to the first insulating portion 210. Since the winding 300 passes through the stator slot 110 of the stator core 100, the winding 300 extends axially along the stator slot 110. Correspondingly, the first insulating portion 210 also extends axially along the stator slot 110 to separate the winding 300 from the inner wall of the stator slot 110. The angle between the second insulating portion 220 and the first insulating portion 210 prevents the second insulating portion 220 from extending completely axially along the stator slot 110, thus also setting an angle between the second insulating portion 220 and the axial direction of the stator slot 110. Specifically, the second insulating portion 220 can extend radially along the stator core 100. This allows the insulating member 200 to provide sufficient creepage distance for both the winding 300 and the stator core 100, while reducing its axial dimension in the stator slot 110. Correspondingly, the axial dimension of the winding 300 in the stator slot 110 can also be reduced, resulting in a lower cost and a more compact structure for the stator of this application. In addition, the reduced axial dimension of the winding 300 in the stator slot 110 also reduces the heat generated by the winding 300, making the motor using the stator of this application operate more safely and stably.

[0043] The first insulating part 210 and the second insulating part 220 can be manufactured by an integral forming process, so that the first insulating part 210 and the second insulating part 220 are an integral structure. In this way, the first insulating part 210 and the second insulating part 220 do not need to be connected separately, and the connection between the first insulating part 210 and the second insulating part 220 is more stable and reliable. Correspondingly, the structure of the insulating 200 is more stable and reliable, which improves the structural stability of the stator of this application and reduces the difficulty and cost of the manufacturing process.

[0044] In some implementations, reference Figure 2 and Figure 3 As shown, in order to ensure that the insulating member 200 can adequately insulate and separate the winding 300 from the stator core 100, the first insulating part 210 can be arranged along the circumference of the stator slot 110. In this way, the insulating member 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.

[0045] Specifically, the shape of the first insulating part 210 can match the slot shape of the stator slot 110 of the stator core 100. The first insulating part 210 has a mounting slot 211, 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 insulating member 200 on all sides, so that the insulating member 200 can fully separate the winding 300 from the stator core 100.

[0046] The outer wall of the first insulating part 210 is fitted to the inner wall of the stator slot 110 of the stator core 100, allowing the first insulating part 210 to have a closer contact with the stator core 100. This reduces the space occupied by the first insulating part 210 within the stator slot 110, allowing for a larger mounting slot 211 that can accommodate a larger winding 300. This results in better stator performance in this application.

[0047] In some implementations, reference Figure 4 As shown, the winding 300 of this application may include multiple conductors 310, which pass through the stator slots 110 and are radially distributed along the stator core 100. Adjacent conductors 310 have gaps to separate them and prevent short circuits caused by contact. The multiple conductors 310 can be bonded to the first insulating part 210, allowing them to be fixed within the mounting groove 211 of the first insulating part 210. Specifically, multiple conductors 310 can be bonded together, and at least one conductor 310 can be bonded to the first insulating part 210, fixing them within the mounting groove 211 of the insulating part 200, thereby fixing the entire winding 300 to the first insulating part 210. In this case, the bonding structure between the multiple conductors 310 provides insulation separation between them. Of course, the multiple wires 310 can also be individually bonded to the first insulating part 210, so that the winding 300 as a whole can be connected and fixed to the first insulating part 210.

[0048] In some implementations, reference Figure 4 As shown, the second insulating portion 220 of this application is connected to the side of the first insulating portion 210 near the center of the stator core 100. In this way, the second insulating portion 220 can be relatively closer to the center of the stator core 100, so that the side of the winding 300 near the center of the stator core 100 can be separated from the stator core 100 by the second insulating portion 220.

[0049] In some embodiments, the number of second insulating portions 220 in this application may be two. Along the axial direction of the stator core 100, the two second insulating portions 220 are connected to both ends of the first insulating portion 210, and both second insulating portions 220 are arranged at an angle to the first insulating portion 210. It should be understood that the winding 300 passes through the stator slot 110 of the stator core 100, such that a portion of the winding 300 is located outside the stator slot 110 and distributed on both sides of the axial direction of the stator slot 110. The two second insulating portions 220 can respectively insulate and separate the two sides of the winding 300 outside the stator slot 110 from the stator core 100, and provide a safe contact distance between the two sides of the winding 300 and the stator core 100. In this way, the length of the winding 300 on both sides outside the stator slot 110 can be reduced, thereby further reducing the length of the winding 300, further making the stator structure of this application more compact, reducing the manufacturing cost of the stator and heat generation.

[0050] In some implementations, reference Figure 4 As shown, in order to make the structure of the stator of this application compact, the second insulating part 220 can be configured to fit against the axial end face of the stator core 100, so that the second insulating part 220 can be closer to the stator core 100, and the axial dimension of the insulating member 200 in the stator core 100 can be further reduced.

[0051] Specifically, when the axial end face of the stator core 100 is perpendicular to the axial direction of the stator core 100, the second insulating part 220 is set at a 90-degree angle to the first insulating part 210, so that the second insulating part 220 can fully fit against the axial end face of the stator core 100.

[0052] In some implementations, reference Figure 4 As shown, since the first insulating portion 210 extends axially along the stator core 100, the first insulating portion 210 has a first thickness along the radial direction of the stator core 100, the first thickness being... Figure 4 D1 in the diagram. Since the second insulating portion 220 extends radially along the stator core 100, it has a second thickness along the axial direction of the stator core 100. The second thickness is... Figure 4 D2 in the figure. The first thickness is less than the second thickness, so the thickness of the first insulating part 210 is thinner, and the structure of the first insulating part 210 can be more compact, so that the space occupied by the first insulating part 210 in the stator slot 110 is smaller. Correspondingly, the size of the winding 300 that can be installed in the stator slot 110 can be larger, and the number of wires 310 can be greater, so as to improve the performance of the stator of this application.

[0053] In some implementations, reference Figure 4As shown, along the radial direction of the stator core 100, the first insulating portion 210 has a third thickness on one side adjacent to the edge of the stator core 100, the third thickness being... Figure 4 In the winding 300, the third thickness (D3) is greater than the first thickness. This ensures that the portion of the winding 300 adjacent to the edge of the stator core 100 also has a safe creepage distance from the stator core 100.

[0054] In some embodiments, to further improve the compactness of the stator structure, the two ends of the first insulating portion 210 are flush with the axial end face of the stator core 100 along the axial direction of the stator core 100. This prevents the first insulating portion 210 from protruding from the surface of the stator core 100, resulting in a smoother surface for the stator. Furthermore, this reduces the amount of insulating material 200 used, further enhancing the compactness of the stator structure.

[0055] In some embodiments, the insulating component 200 of this application may also be a thermosetting injection molded structural component, so that the insulating component 200 can be formed by thermosetting injection molding, thus making the connection between the insulating component 200 and the stator core 100 more stable and reliable.

[0056] Specifically, in the fabrication of the stator of this application, the insulating component 200, which becomes fluid after heating, can be injection molded onto the stator core 100. Further heating of the fluid insulating component 200 can fix it to the stator core 100. The first insulating portion 210 is thermosetting and injection molded into the stator slot 110 of the stator core 100, ensuring that the first insulating portion 210 fully matches the slot shape of the stator slot 110. This allows the first insulating portion 210 to better cover the inner wall of the stator slot 110, effectively separating the winding 300 from the stator core 100. The second insulating portion 220 is thermosetting and injection molded onto the axial end face of the stator core 100.

[0057] 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.

[0058] 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.

[0059] 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.

[0060] 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).

[0061] 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.

[0062] 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 passes through the stator core (100) along the axial direction of the stator core (100). The insulating component (200) includes a plurality of integrally connected first insulating portions (210) and second insulating portions (220). The first insulating portions (210) are disposed in the stator slot (110), and the second insulating portions (220) are located outside the stator slot (110), and the second insulating portions (220) are disposed at an angle to the first insulating portions (210). The winding (300) is inserted into the stator slot (110), and the first insulating part (210) is located between the inner wall of the stator slot (110) and the winding (300).

2. The stator according to claim 1, characterized in that, The first insulating part (210) is arranged circumferentially along the stator slot (110), the outer wall of the insulating member (200) is in contact with the inner wall of the stator slot (110), the first insulating part (210) has a mounting slot (211), and the winding (300) passes through the mounting slot (211).

3. The stator according to claim 2, characterized in that, The second insulating part (220) is connected to the side of the first insulating part (210) adjacent to the center of the stator core (100).

4. The stator according to claim 3, characterized in that, There are two second insulating parts (220), and along the axial direction of the stator core (100), the two second insulating parts (220) are connected to the two ends of the first insulating part (210).

5. The stator according to any one of claims 1-4, characterized in that, The second insulating part (220) is in contact with the axial end face of the stator core (100).

6. The stator according to any one of claims 1-4, characterized in that, Along the radial direction of the stator core (100), the first insulating portion (210) has a first thickness on one side near the center of the stator core (100), and along the axial direction of the stator core (100), the second insulating portion (220) has a second thickness, the first thickness being less than the second thickness.

7. The stator according to claim 6, characterized in that, Along the radial direction of the stator core (100), the first insulating portion (210) has a third thickness on one side adjacent to the edge of the stator core (100), the third thickness being greater than the first thickness.

8. The stator according to any one of claims 1-4, characterized in that, Along the axial direction of the stator core (100), both ends of the first insulating part (210) are flush with the axial end face of the stator core (100).

9. The stator according to claim 1, characterized in that, The insulating component (200) is a thermosetting injection molded structural component, and the insulating component (200) is an integral structural component.

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

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