Injection molded stator and motor

Abstract

The utility model provides an injection molding stator and motor, injection molding stator includes: stator main part, stator main part includes the stator core after winding and sets up multiple windings on the stator core, multiple pins, multiple pins are along the circumferential distribution of stator main part and part embed stator main part, three lead-out wires are used for connecting with external power supply, circuit board subassembly, circuit board subassembly includes the first circuit board and second circuit board of welding in proper order, first circuit board sets up at one side of stator main part, second circuit board sets up at the side of first circuit board away from stator main part, wherein, first circuit board and each pin all weld, second circuit board and three in multiple pins weld, second circuit board and three lead-out wires correspondingly weld, to solve the problem that the mode of adopting the wire clamp lead-out in the BMC injection molding mode in prior art can easily lead to lead-out difficult and occupy larger space, thereby influence the compactness of the structure of motor.

Description

Technical Field

[0001] This utility model relates to the field of motor manufacturing technology, and more specifically, to an injection-molded stator and motor. Background Technology

[0002] In the field of servo motors, traditional stator insulation protection measures mainly include impregnation and epoxy resin potting technology. Although these processes improve the electrical performance and lifespan of the motor to some extent, they also have significant limitations.

[0003] The impregnation process involves immersing the entire stator in an insulating varnish after the stator coils are completed, and then heating it to cure it, thus achieving insulation. However, this process is not only time-consuming, but the cured varnish film is often quite brittle and hard, which can lead to hardening of the enameled wire and subsequent breakage. To reduce the breakage rate, the curing time of the varnish film is usually extended, which undoubtedly further reduces production efficiency and increases costs. In addition, the curing of the varnish film can also cause deformation of the inner circle of the stator, affecting the operating performance of the motor.

[0004] Epoxy resin potting technology, as another commonly used insulation method, can solve the above problems to some extent, but it still has shortcomings. After the servo motor stator winding is completed, epoxy resin is poured into the stator and then cured externally by heating. Although this method can provide good insulation, the relatively high curing shrinkage rate of epoxy resin may generate stress inside the stator, affecting its long-term stability. At the same time, the long curing time of epoxy resin also poses a challenge to production efficiency.

[0005] In recent years, with the increasing demand for high precision, high response speed, and high reliability in servo motors, BMC injection molding technology has gradually gained attention as an efficient and environmentally friendly insulating encapsulation method. BMC (Bulk Molding Compound) is a pre-impregnated composite material that cures rapidly during injection molding, providing excellent filling and virtually eliminating air bubbles, making it suitable for encapsulating motor stators. Especially when encapsulating DC motor stators, BMC allows for one-time molding, significantly improving production efficiency. However, existing BMC injection molding methods have encountered new challenges when applied to servo motor stators, primarily in stator cable exits. Since the servo motor stator is completely encapsulated by the injection molding compound, using cable clamps for cable exits not only occupies a significant amount of space but is also unsuitable for small-diameter motors. The cable clamp design increases installation complexity and affects the overall protection level and structural compactness of the motor. Utility Model Content

[0006] The main purpose of this utility model is to provide an injection-molded stator and motor to solve the problem that the wire clamp method used in the existing BMC injection molding process is prone to difficulties in wire exit and occupies a large space, thus affecting the structural compactness of the motor.

[0007] To achieve the above objectives, according to one aspect of the present invention, an injection-molded stator is provided, comprising: a stator body, the stator body including a wound stator core and a plurality of windings disposed on the stator core; a plurality of pins, the plurality of pins being distributed circumferentially along the stator body and partially embedded in the stator body; three lead wires for connecting to an external power source; and a circuit board assembly, the circuit board assembly including a first circuit board and a second circuit board sequentially soldered together, the first circuit board being disposed on one side of the stator body, and the second circuit board being disposed on the side of the first circuit board away from the stator body; wherein, the first circuit board is soldered to each of the pins, the second circuit board is soldered to three of the plurality of pins, and the second circuit board is soldered to the three lead wires in a one-to-one correspondence.

[0008] Furthermore, multiple pins extend from the stator body and pass through the circuit board assembly. Multiple pin pads are provided on the outer wall surface of the circuit board assembly. The multiple pin pads are arranged circumferentially around the stator body. The multiple pins are arranged one-to-one with the multiple pin pads, and each pin is soldered to the corresponding pin pad.

[0009] Further, the first circuit board includes: a first board body, which is soldered to at least one side of the stator body, the first board body including a first inner wall surface and a first outer wall surface, the first board body also including a plurality of first pad holes spaced apart on the first outer wall surface; a plurality of first pin pads, which are disposed one-to-one in the plurality of first pad holes, and the plurality of first pin pads are soldered one-to-one with the plurality of pins; wherein, a portion of the plurality of first pin pads are connected by a plurality of first connecting lines on the first board body.

[0010] Furthermore, the multiple first pin pads are grouped in pairs, and the first circuit board also includes: multiple first process holes, each of which penetrates the first board body. The multiple first process holes and at least a portion of the multiple groups of first pin pads are staggered along the circumference of the first board body to guide the molding compound to the stator body during injection molding; and multiple first positioning grooves, which penetrate the first board body and are spaced apart from the multiple first process holes. The multiple first positioning grooves are spaced between the first first process hole and the last first process hole to cooperate with the positioning keys of the welding fixture of the injection molded stator during the welding of the first circuit board.

[0011] Further, the second circuit board includes: a second board body that contacts one-quarter of the first board body, the second board body including a second inner wall surface and a second outer wall surface, the second board body including a plurality of second pad holes spaced apart on the second outer wall surface; three second pin pads that are correspondingly disposed on three of the plurality of second pad holes, the three second pin pads correspondingly disposed on three of the plurality of first pin pads for soldering to three of the plurality of pins; and three lead-out pads that are spaced apart on the second board body, the three lead-out pads and the three second pin pads being connected to each other through three second connecting lines on the second board body, and the three lead-out pads being soldered to three lead-out lines.

[0012] Furthermore, the second circuit board also includes a plurality of second positioning grooves, which are disposed through the second board body and spaced apart on the second board body, so as to cooperate with the positioning keys of the welding fixture of the injection molded stator when welding the second circuit board.

[0013] Furthermore, the first plate body includes multiple first plate body layers stacked sequentially, and each first connecting line is disposed in the multiple first plate body layers; the second plate body includes multiple second plate body layers stacked sequentially, and each second connecting line is disposed in the other second plate body layers except for the first second plate body layer and the last second plate body layer; wherein, the multiple first connecting lines are located at positions of the first plate body that do not contact the second plate body, the welding fixture of the injection molded stator is provided with a first bearing surface for contacting the first plate body, and the welding fixture is also provided with a relief groove located on the first bearing surface, and the second plate body is located in the relief groove.

[0014] Furthermore, the injection-molded stator also includes: multiple skeletons, which are disposed at the ends of the stator core and spaced apart around the stator core to support the windings. Each skeleton is provided with two pin slots, and each pin is inserted into the corresponding pin slot.

[0015] According to another aspect of the present invention, an electric motor is provided, comprising: a motor housing having a front opening and a rear opening, and having a front bearing portion and a rear bearing portion for fixing a bearing; an injection-molded stator, the injection-molded stator being the aforementioned injection-molded stator, the injection-molded stator being disposed within the motor housing; a rotor assembly, a portion of the rotor assembly being rotatably disposed within the motor housing and located in the inner hole of the injection-molded stator; a front end cover and a rear end cover, respectively closing the front opening and the rear opening of the motor housing; an encoder, the encoder being disposed on the side of the rear end cover away from the front end cover; and an encoder end cover, the encoder end cover being disposed on the side of the encoder away from the rear end cover.

[0016] Furthermore, the motor housing and the injection-molded stator are clearance-fitted. The motor housing is provided with a protrusion, and the outer circumferential surface of the injection-molded stator is provided with a groove. The protrusion is used to engage with the groove to limit the movement of the injection-molded stator.

[0017] By applying the technical solution of this utility model, this application utilizes a double-layer circuit board structure, namely the combined use of a first circuit board and a second circuit board, to ensure reliable electrical connection between all windings and pins. Simultaneously, the second circuit board is soldered to three selected pins, and then to the lead wires, achieving efficient current distribution and signal transmission. This design not only improves the output power and response speed of the servo motor but also reduces the failure rate caused by unstable connections. Furthermore, the introduced second circuit board eliminates concerns about the molding compound covering the solder pads during injection molding, avoiding the leakage problem that occurs in traditional BMC injection molding processes. It also ensures that the lead wire solder pads remain intact. The improved structural integrity and flatness simplify the design and operation of injection molds, shorten the assembly time between the stator and the housing, and reduce production costs. The injection molding process used in this application can completely encapsulate the windings and pins of the stator body, increasing the mechanical strength of the stator assembly. At the same time, the insulating layer formed by the injection molding can effectively isolate the external environment and improve the protection level of the motor. Especially under harsh working conditions with high dust and humidity, it improves the durability of the motor and solves the problem that the wire clamp method used in the existing BMC injection molding method is prone to difficulties in wire exit and occupies a large space, thus affecting the structural compactness of the motor. Attached Figure Description

[0018] The accompanying drawings, which form part of this application, are used to provide a further understanding of the present invention. The illustrative embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an undue limitation of the present invention. In the drawings:

[0019] Figure 1 A schematic diagram of an embodiment of the encapsulated stator according to the present invention is shown; and

[0020] Figure 2 A schematic diagram of the structure of an embodiment of the first circuit board according to the present invention is shown;

[0021] Figure 3 A schematic diagram of an embodiment of the second circuit board according to the present invention is shown;

[0022] Figure 4 A schematic diagram of an embodiment of the welding fixture in the encapsulated stator according to the present invention is shown;

[0023] Figure 5 A schematic diagram of an embodiment in which a first circuit board and a second circuit board are soldered onto a plastic-encapsulated stator according to the present invention is shown.

[0024] Figure 6 A schematic diagram of an embodiment of the molded stator frame and pins according to the present invention is shown;

[0025] Figure 7 A front view of an embodiment of the present invention is shown after the first and second circuit boards have been soldered together;

[0026] Figure 8 A front view of an embodiment of the circuit board assembly according to the present invention after molding is shown;

[0027] Figure 9 A structural schematic diagram of an embodiment of the motor according to the present invention is shown;

[0028] Figure 10 It shows Figure 9 The enlarged view of point S shown below;

[0029] Figure 11 A schematic diagram of an embodiment of the rotor assembly according to the present invention is shown.

[0030] The above figures include the following reference numerals:

[0031] 10. Stator body; 110. Stator core; 120. Windings;

[0032] 20. Insert pin;

[0033] 330. Pin pads;

[0034] 30. Circuit board assembly; 310. First circuit board; 311. First board body; 3111. First inner wall surface; 3112. First outer wall surface; 313. First process hole; 314. First positioning groove; 312. First pin pad;

[0035] 320. Second circuit board; 321. Second board body; 3211. Second inner wall surface; 3212. Second outer wall surface; 322. Second pin pad; 323. Outgoing wire pad; 324. Second positioning groove;

[0036] 40. Welding fixture; 410. Locating key; 420. First bearing surface; 430. Clearance groove;

[0037] 50. Skeleton; 510. Pin slot;

[0038] 60. Motor housing; 610. Protrusion;

[0039] 70. Injection-molded stator; 710. Groove;

[0040] 90. Front cover; 100. Rear cover; 200. Encoder; 300. Encoder end cover;

[0041] 80. Rotor assembly; 810. Rotating shaft; 820. Rotating iron core; 830. Magnet; 840. Front bearing; 850. Rear bearing. Detailed Implementation

[0042] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0043] like Figures 1 to 11 As shown, the injection-molded stator of this application includes: a stator body 10, which includes a wound stator core 110 and multiple windings 120 disposed on the stator core 110; multiple pins 20, which are distributed circumferentially along the stator body 10 and partially embedded in the stator body 10; three lead wires for connecting to an external power source; and a circuit board assembly 30, which includes a first circuit board 310 and a second circuit board 320 sequentially soldered together. The first circuit board 310 is disposed on one side of the stator body 10, and the second circuit board 320 is disposed on the side of the first circuit board 310 away from the stator body 10. The first circuit board 310 is soldered to each of the pins 20, the second circuit board 320 is soldered to three of the multiple pins 20, and the second circuit board 320 is soldered to the three lead wires one-to-one.

[0044] Thus, this application, through the use of a double-layer circuit board structure—namely, the first circuit board 310 and the second circuit board 320—ensures reliable electrical connection between all windings and pins 20. Simultaneously, the second circuit board 320 is soldered to three selected pins 20, and then to the lead wires, achieving efficient current distribution and signal transmission. This design not only improves the output power and response speed of the servo motor but also reduces the failure rate caused by unstable connections. Furthermore, the introduced second circuit board 320 eliminates concerns about molded material covering the solder pads during injection molding, avoiding material leakage problems common in traditional BMC injection molding processes. It also ensures that the lead wire solder pads maintain their structural integrity. The integrity and flatness of the molds simplify the design and operation of the injection molds, shorten the assembly time between the stator and the housing, and reduce production costs. The injection molding process used in this application can completely wrap the multiple windings 120 and pins 20 of the stator body 10, increasing the mechanical strength of the stator assembly. At the same time, the insulating layer formed by the injection molding can effectively isolate the external environment and improve the protection level of the motor. Especially under harsh working conditions with high dust and humidity, it improves the durability of the motor and solves the problem that the wire clamp method used in the existing BMC injection molding method is prone to difficulties in wire exit and occupies a large space, thus affecting the structural compactness of the motor.

[0045] Specifically, multiple pins 20 extend from the stator body 10 and pass through the circuit board assembly 30. Multiple pin pads 330 are provided on the outer wall surface of the circuit board assembly 30. The multiple pin pads 330 are arranged circumferentially around the stator body 10. The multiple pins 20 are arranged one-to-one with the multiple pin pads 330, and each pin 20 is soldered to the corresponding pin pad 330.

[0046] The one-to-one welding of pins 20 to pin pads 330 ensures the electrical continuity and stability between winding 120 and external circuits. This point-to-point connection reduces contact resistance during electrical connection, lowers the risk of connection point detachment or short circuit, and enhances the overall electrical performance and long-term reliability of the motor. Through the optimization of positioning and welding processes, the circuit board assembly 30 can be protected during injection molding, especially to prevent the molding compound from overflowing into the pad area, thereby simplifying the injection molding process and improving production efficiency.

[0047] Specifically, the first circuit board 310 includes: a first board body 311, which is soldered to at least one side of the stator body 10. The first board body 311 includes a first inner wall surface 3111 and a first outer wall surface 3112. The first board body 311 also includes a plurality of first pad holes spaced apart on the first outer wall surface 3112; a plurality of first pin pads 312, which are disposed one-to-one with the plurality of first pad holes, and are soldered one-to-one with the plurality of pins 20; wherein, a portion of the plurality of first pin pads 312 are connected by a plurality of first connecting lines on the first board body 311.

[0048] By placing the first pin pads 312 one-to-one in the first pad holes and soldering them to the pins 20, a stable electrical connection point is formed. This design ensures that the connection between the winding and the circuit board will not loosen even when the motor is running at high speed, thereby improving the reliability and stability of the electrical connection. The multiple first connection lines on the first circuit board 310 connect to the first pin pads 312, realizing an optimized internal layout of the circuit, reducing signal transmission paths, improving signal transmission efficiency, and reducing signal loss and interference, which is crucial for the precise control of the servo motor.

[0049] Specifically, the multiple first pin pads 312 are grouped in pairs, and the first circuit board 310 also includes: multiple first process holes 313, each of which is disposed through the first board body 311. The multiple first process holes 313 and at least a portion of the multiple groups of first pin pads 312 are staggered along the circumference of the first board body 311 to guide the molding compound to the stator body 10 during injection molding; and multiple first positioning grooves 314, which are disposed through the first board body 311. The multiple first positioning grooves 314 are spaced apart from the multiple first process holes 313. The multiple first positioning grooves 314 are spaced apart between the first first process hole 313 and the last first process hole 313 to cooperate with the positioning key 410 of the injection molding stator welding fixture 40 when welding the first circuit board 310.

[0050] The design of multiple first process holes 313 significantly improves the flowability of the molding compound during injection molding, ensuring that the molding compound is evenly filled into all gaps of the stator body 10, avoiding voids and air bubbles during injection molding, and improving the bonding force between the molding compound and the winding 120, pins 20, and first circuit board 310. This results in a denser insulation layer after injection molding, improving the motor's insulation performance and reducing the risk of electrical faults. The first process holes 313 also act as heat conduction channels during injection molding, helping to conduct the heat generated inside the stator body 10 by the current to the molding compound layer more quickly, and then dissipate it to the motor housing through the molding compound, thereby improving the motor's thermal conductivity, reducing hot spot temperatures, and ensuring stable operation of the motor under long-term high loads.

[0051] Specifically, the second circuit board 320 includes: a second board body 321, which contacts a quarter of the first board body 311; the second board body 321 includes a second inner wall surface 3211 and a second outer wall surface 3212; the second board body 321 includes a plurality of second pad holes spaced apart on the second outer wall surface 3212; three second pin pads 322, which are correspondingly disposed on three of the plurality of second pad holes, and are correspondingly disposed with three of the plurality of first pin pads 312 for soldering with three of the plurality of pins 20; and three lead-out pads 323, which are spaced apart on the second board body 321, and are connected to the three second pin pads 322 through three second connecting lines on the second board body 321, and are soldered with the three lead-out lines.

[0052] The area of ​​the second board 321 is set to one-quarter of that of the first board 311, and three second pin pads 322 and three lead-out pads 323 are only provided in this part, thus simplifying the circuit interface. This design reduces the size of the motor, while optimizing the layout of the electrical interface, facilitating the access of external power and control signals, and improving the versatility and convenience of the motor. The three second pin pads 322 on the second circuit board 320 are connected and soldered to the corresponding three first pin pads 312 on the stator body 10, establishing a double-protected electrical connection, ensuring the stability of signal transmission and the uniformity of current distribution under extreme conditions.

[0053] Specifically, the second circuit board 320 also includes: a plurality of second positioning grooves 324, which are disposed through the second plate body 321 and are spaced apart on the second plate body 321, so as to cooperate with the positioning key 410 of the welding fixture 40 of the injection molded stator when welding the second circuit board 320.

[0054] The precise engagement between the second positioning groove 324 and the positioning key 410 of the welding fixture 40 effectively controls the relative position of the second circuit board 320 during the welding process, ensuring that the three second pin pads 322 are aligned with the corresponding pins 20 and the lead wire pads 323 are aligned with the lead wires, thereby improving the quality and reliability of the electrical connection.

[0055] The presence of the positioning slot provides a positioning reference for automated welding equipment, enabling the machine to quickly and accurately position the second circuit board 320, greatly reducing the time for manual adjustment and positioning, accelerating the welding speed, improving production efficiency, and reducing production costs.

[0056] Specifically, the first plate 311 includes multiple first plate layers stacked sequentially, and each first connecting line is disposed in the multiple first plate layers; the second plate 321 includes multiple second plate layers stacked sequentially, and each second connecting line is disposed in the other second plate layers except for the first second plate layer and the last second plate layer; wherein, the multiple first connecting lines are located at positions of the first plate 311 that do not contact the second plate 321, the welding fixture 40 of the injection molded stator is provided with a first bearing surface 420 for contacting the first plate 311, and the welding fixture 40 is also provided with a relief groove 430 located on the first bearing surface 420, and the second plate 321 is located in the relief groove 430.

[0057] The multilayer board structure increases the thickness and strength of the circuit board, enabling it to withstand higher thermal stress during injection molding without deformation. It also provides better mechanical protection and reduces damage caused by external impacts. The first and second connecting lines are respectively set between different board layers, avoiding direct crossing between signal lines, reducing the risk of electromagnetic interference, and improving the stability and integrity of signal transmission.

[0058] The precise positioning of the first bearing surface 420 and the clearance groove 430 on the welding fixture 40 ensures the correct alignment of the first plate 311 and the second plate 321 during welding, improves assembly accuracy, simplifies the production process, and reduces the error rate of manual assembly.

[0059] Specifically, the injection-molded stator also includes: multiple skeletons 50, which are disposed at the ends of the stator core 110 and are spaced apart around the stator core 110 to support the winding 120. Each skeleton 50 is provided with two pin slots 510, and each pin 20 is inserted into the corresponding pin slot 510.

[0060] The multiple bobbins 50 can effectively support the winding 120, preventing the winding from vibrating or displacing under high-speed rotation of the motor or specific working conditions, thus improving the smoothness and reliability of motor operation. By setting pin slots 510 on the bobbins 50, a stable connection between the pins 20 and the winding 120 is ensured, reducing the problem of poor contact or breakage of electrical connections caused by vibration, and improving the electrical performance and service life of the motor.

[0061] The use of skeleton 50 provides a supporting structure for the injection molding process, which helps the molding compound to fill evenly, reduces the deformation of winding 120 during injection molding, and prevents the molding compound from covering critical electrical connection parts, thereby improving the pass rate of injection molded products.

[0062] The motor of this application includes: a motor housing 60 having a front opening and a rear opening, and having a front bearing portion and a rear bearing portion for fixing bearings; an injection-molded stator 70, which is the injection-molded stator described above, and is disposed within the motor housing 60; a rotor assembly 80, a portion of which is rotatably disposed within the motor housing 60 and located within the inner hole of the injection-molded stator 70; a front end cover 90 and a rear end cover 100, which respectively close the front opening and the rear opening of the motor housing 60; an encoder 200 disposed on the side of the rear end cover 100 away from the front end cover 90; and an encoder end cover 300 disposed on the side of the encoder 200 away from the rear end cover 100.

[0063] In this application, the tight fit between the motor housing 60, the injection-molded stator 70, the rotor assembly 80, and the front cover 90 and rear cover 100 constructs a stable and well-sealed motor system that can effectively resist interference from the external environment and maintain the stability and accuracy of motor operation. The front bearing and rear bearing designed on the motor housing 60 provide precise rotational support for the rotor assembly 80, reducing friction and wear between the rotor and stator and extending the service life of the motor.

[0064] The use of injection-molded stator 70, especially the optimization of its internal structure, such as the design of frame 50 and multi-layer circuit boards, helps to improve electromagnetic performance, reduce magnetic reluctance and eddy current losses. At the same time, the thermal conductivity of the molding compound and the compactness of the structure improve the heat dissipation efficiency inside the motor, reduce the operating temperature, and further improve the motor's working efficiency and reliability.

[0065] Specifically, the motor housing 60 and the injection-molded stator 70 are clearance-fitted. The motor housing 60 is provided with a protrusion 610, and the outer peripheral surface of the injection-molded stator 70 is provided with a groove 710. The protrusion 610 is used to insert and fit with the groove 710 to limit the position of the injection-molded stator 70.

[0066] The insertion and engagement of the protrusion 610 and the groove 710 can accurately position the injection-molded stator 70 in the motor housing 60, avoiding stator displacement caused by vibration during motor operation, and improving the assembly accuracy and operational stability of the motor. By using a clearance fit instead of an interference fit, the injection-molded stator 70 is allowed to have appropriate movement space during thermal expansion, which can reduce the impact of thermal stress on the concentricity of the motor, and at the same time avoid friction or damage between the stator and the housing caused by thermal expansion.

[0067] Specifically, the motor housing 60 and the stator core 110 of the unmolded stator are in clearance fit. The protrusion 610 of the motor housing 60 is used to position the unmolded stator. After the stator is placed into the motor housing 60, it is molded along with the motor housing 60. After molding, the protrusion 610 plays a limiting role.

[0068] Specifically, the rotor assembly 80 further includes: a rotating shaft 810, which is partially rotatably disposed within the motor housing 60; a rotating iron core 820, which is fixed on the rotating shaft 810 and has a magnet 830 disposed on it to interact with the magnetic field generated by the multiple windings 120 of the injection-molded stator 70 to generate rotational torque; a front bearing 840 and a rear bearing 850, with the front bearing 840 installed in the front bearing section and the rear bearing 850 installed in the rear bearing section, and the two ends of the rotating shaft 810 respectively cooperating with the front bearing 840 and the rear bearing 850.

[0069] The magnet 830 is fixed on the rotating iron core 820 and interacts with the magnetic field generated by the multiple windings 120 of the injection-molded stator 70 to form an efficient magnetic circuit, thereby enhancing the torque output capability of the motor and improving the dynamic response characteristics and load capacity of the motor.

[0070] The front bearing 840 and rear bearing 850 in this application provide stable support, reduce the radial and axial displacement of the rotating shaft 810 during high-speed rotation, effectively extend the service life of the bearings, reduce the wear of the rotor assembly 80, and improve the service life and reliability of the servo motor.

[0071] As can be seen from the above description, the embodiments of this utility model achieve the following technical effects:

[0072] The injection-molded stator of this application includes: a stator body 10, which includes a wound stator core 110 and multiple windings 120 disposed on the stator core 110; multiple pins 20, which are distributed circumferentially along the stator body 10 and partially embedded in the stator body 10; three lead wires for connecting to an external power source; and a circuit board assembly 30, which includes a first circuit board 310 and a second circuit board 320 sequentially soldered together. The first circuit board 310 is disposed on one side of the stator body 10, and the second circuit board 320 is disposed on the side of the first circuit board 310 away from the stator body 10. The first circuit board 310 is soldered to each of the pins 20, the second circuit board 320 is soldered to three of the multiple pins 20, and the second circuit board 320 is soldered to the three lead wires one-to-one.

[0073] As can be seen, this application, through the use of a double-layer circuit board structure, namely the cooperation of the first circuit board 310 and the second circuit board 320, can ensure a reliable electrical connection between all windings and pins 20. Simultaneously, the second circuit board 320 is soldered to three selected pins 20, and then to the lead wires, achieving efficient current distribution and signal transmission. This design not only improves the output power and response speed of the servo motor but also reduces the failure rate caused by unstable connections. Furthermore, the introduced second circuit board 320 eliminates concerns about the molding compound covering the solder pads during injection molding, avoiding the leakage problem that occurs in traditional BMC injection molding processes. It also allows the lead wire solder pads to maintain their structural integrity. The integrity and flatness of the molds simplify the design and operation of the injection molds, shorten the assembly time between the stator and the housing, and reduce production costs. The injection molding process used in this application can completely wrap the multiple windings 120 and pins 20 of the stator body 10, increasing the mechanical strength of the stator assembly. At the same time, the insulating layer formed by the injection molding can effectively isolate the external environment and improve the protection level of the motor. Especially under harsh working conditions with high dust and humidity, it improves the durability of the motor and solves the problem that the wire clamp method used in the existing BMC injection molding method is prone to difficulties in wire exit and occupies a large space, thus affecting the structural compactness of the motor.

[0074] 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 this application. 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.

[0075] 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 application. 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.

[0076] In the description of this application, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is usually based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this application and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this application; the directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0077] 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.

[0078] 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 application.

[0079] The above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. An injection-molded stator, characterized in that, include: The stator body (10) includes a wound stator core (110) and a plurality of windings (120) disposed on the stator core (110). Multiple pins (20) are distributed circumferentially along the stator body (10) and partially embedded in the stator body (10). Three lead-out cables are used for connecting to an external power supply; The circuit board assembly (30) includes a first circuit board (310) and a second circuit board (320) soldered in sequence. The first circuit board (310) is disposed on one side of the stator body (10), and the second circuit board (320) is disposed on the side of the first circuit board (310) away from the stator body (10). The first circuit board (310) is soldered to each of the pins (20), the second circuit board (320) is soldered to three of the multiple pins (20), and the second circuit board (320) is soldered to the three lead wires one by one.

2. The injection-molded stator according to claim 1, characterized in that, The plurality of pins (20) extend from the stator body (10) and pass through the circuit board assembly (30). The outer wall surface of the circuit board assembly (30) is provided with a plurality of pin pads (330). The plurality of pin pads (330) are arranged circumferentially around the stator body (10). The plurality of pins (20) are arranged in a one-to-one correspondence with the plurality of pin pads (330). Each of the pins (20) is soldered to the corresponding pin pad (330).

3. The injection-molded stator according to claim 1, characterized in that, The first circuit board (310) includes: The first plate (311) is welded to at least one side of the stator body (10). The first plate (311) includes a first inner wall surface (3111) and a first outer wall surface (3112). The first plate (311) also includes a plurality of first pad holes spaced apart on the first outer wall surface (3112). Multiple first pin pads (312) are provided one-to-one with the multiple first pin holes, and the multiple first pin pads (312) are soldered one-to-one with the multiple pins (20); Some of the plurality of first pin pads (312) are connected by a plurality of first connection lines on the first board body (311).

4. The injection-molded stator according to claim 3, characterized in that, The plurality of first pin pads (312) are grouped in pairs, and the first circuit board (310) further includes: Multiple first process holes (313) are provided, each of which penetrates the first plate (311). The multiple first process holes (313) and at least a portion of the multiple sets of first pin pads (312) are staggered along the circumference of the first plate (311) to guide the molding compound to the stator body (10) during injection molding. Multiple first positioning grooves (314) are provided through the first plate body (311). The multiple first positioning grooves (314) are spaced apart from the multiple first process holes (313). The multiple first positioning grooves (314) are spaced apart between the first first process hole (313) and the last first process hole (313) so as to cooperate with the positioning key (410) of the welding fixture (40) of the injection molded stator when welding the first circuit board (310).

5. The injection-molded stator according to claim 3, characterized in that, The second circuit board (320) includes: The second plate (321) is in contact with one-quarter of the first plate (311). The second plate (321) includes a second inner wall surface (3211) and a second outer wall surface (3212). The second plate (321) includes a plurality of second pad holes spaced apart on the second outer wall surface (3212). Three second pin pads (322) are provided on three of the plurality of second pin holes in a one-to-one correspondence. The three second pin pads (322) are provided in a corresponding manner to three of the plurality of first pin pads (312) so as to be soldered to three of the plurality of pins (20) in a one-to-one correspondence. Three lead pads (323) are spaced apart on the second board (321). The three lead pads (323) and the three second pin pads (322) are connected one-to-one through three second connecting lines on the second board (321), and the three lead pads (323) are soldered one-to-one with the three lead lines.

6. The injection-molded stator according to claim 5, characterized in that, The second circuit board (320) also includes: Multiple second positioning slots (324) are provided through the second plate (321) and are spaced apart on the second plate (321) so as to cooperate with the positioning key (410) of the welding fixture (40) of the injection molded stator when welding the second circuit board (320).

7. The injection-molded stator according to claim 6, characterized in that, The first plate (311) includes a plurality of first plate layers stacked sequentially, and each of the first connecting lines is disposed in the plurality of first plate layers; The second plate (321) includes a plurality of second plate layers stacked sequentially, and each of the second connecting lines is disposed in the other second plate layers except for the first second plate layer and the last second plate layer; The plurality of first connecting lines are located at positions on the first plate (311) that do not contact the second plate (321). The welding fixture (40) of the injection stator is provided with a first bearing surface (420) for contacting the first plate (311). The welding fixture (40) is also provided with a relief groove (430) located on the first bearing surface (420). The second plate (321) is located in the relief groove (430).

8. The injection-molded stator according to claim 2, characterized in that, The injection-molded stator also includes: Multiple skeletons (50) are disposed at the ends of the stator core (110) and are spaced apart around the stator core (110) to support the winding (120). Each skeleton (50) is provided with two pin slots (510), and each pin (20) is inserted into the corresponding pin slot (510).

9. An electric motor, characterized in that, include: The motor housing (60) has a front opening and a rear opening, and is provided with a front bearing portion and a rear bearing portion for fixing the bearing; Injection molded stator (70), wherein the injection molded stator (70) is the injection molded stator according to any one of claims 1 to 8, and the injection molded stator (70) is disposed inside the motor housing (60); A rotor assembly (80), a portion of which is rotatably disposed within the motor housing (60) and located within the inner bore of the injection-molded stator (70); The front cover (90) and the rear cover (100) respectively close the front opening and the rear opening of the motor housing (60); An encoder (200) is disposed on the side of the rear end cover (100) away from the front end cover (90); An encoder end cover (300) is disposed on the side of the encoder (200) away from the rear end cover (100).

10. The motor according to claim 9, characterized in that, The motor housing (60) and the injection-molded stator (70) are clearance-fitted. The motor housing (60) is provided with a protrusion (610), and the injection-molded stator (70) is provided with a groove (710) on its outer peripheral surface. The protrusion (610) is used to insert into the groove (710) to limit the position of the injection-molded stator (70).

Images