Injection molded stator and bldc motor using the same

Abstract

The utility model discloses a kind of injection molding stator and the BLDC motor applied thereto, the injection molding stator includes stator core, insulating end portion installed outside stator core, stator coil around setting outside insulating end portion, baffle plate, and injection molding body, injection molding body is wrapped stator core, insulating end portion, stator coil and baffle plate, the end face of its insulating end portion is equipped with several mounting platforms, each mounting platform protrudes with several mounting columns, baffle plate includes several baffle sub-plates, each baffle sub-plate is equipped with the mounting hole corresponding with mounting column setting, baffle sub-plate is installed on mounting platform, mounting column is inserted in mounting hole and baffle sub-plate is fixed on insulating end portion. Baffle sub-plate is not limited by the size of stator core, can be applied on different size stator, design cost and production cost are saved;Baffle sub-plate is fixed on insulating end portion, so that injection molding does not need to use thimble to carry out the fixation of baffle sub-plate, guarantee the insulation of stator assembly.

Description

Technical Field

[0001] This utility model relates to an injection-molded stator and its application in BLDC motors. Background Technology

[0002] Existing encapsulated BLDC motors use BMC injection-molded stators. After the stator core assembly is wound, terminals are typically used to connect the U, V, W phases of the windings to the common terminal. During stator injection molding, to fix the terminal positions, cover plates are usually used to secure the terminals. The position is then fixed by ejector pins in the molded stator pressing the cover plates axially from the stator. However, this structure has the following disadvantages: 1. Different core outer diameters require different sized cover plates. When there are many models, many sets of molds are needed to match different cover plates, increasing development costs and time. 2. Once installed on the stator assembly, the existing cover plates cannot be fixed in axial position, posing a risk of being detached by the BMC material during injection molding. Therefore, ejector pins are needed to press the cover plates, creating ejector pin holes that allow water to easily enter the stator and damage the motor. Utility Model Content

[0003] This invention provides an injection-molded stator and its application in BLDC motors, which solves the problem that different cover plates are required for injection-molded stators with different core outer diameters in the prior art, resulting in high production costs.

[0004] The technical solution of this utility model is implemented as follows:

[0005] The first objective of this utility model is to provide an injection-molded stator, comprising a stator core, an insulating end installed outside the stator core, a stator coil wound around the insulating end, a cover plate, and an injection-molded body. The injection-molded body encapsulates the stator core, the insulating end, the stator coil, and the cover plate. The invention is characterized in that: the end face of the insulating end is provided with several mounting platforms, each mounting platform protruding with several mounting posts; the cover plate includes several cover plates, each cover plate having mounting holes corresponding to the mounting posts; the cover plates are mounted on the mounting platforms, and the mounting posts are inserted into the mounting holes, fixing the cover plates to the insulating end.

[0006] The number of the aforementioned mounting platform and cover plate is four. The mounting platform is provided with a slot, and the plurality of mounting posts are located around the slot. The cover plate is provided with a through hole corresponding to the slot. A wire inlet pin is installed in the slot. The bottom of the wire inlet pin is connected to the stator coil, and the top of the wire inlet pin passes through the through hole and is connected to the lead wire.

[0007] The top of the aforementioned inlet pin is provided with a positioning hole, one end of the lead wire is inserted into the positioning hole, and the other end of the lead wire extends out of the injection molded body.

[0008] The four aforementioned baffle plates include three three-phase baffle plates and one ground wire baffle plate. The four incoming pins include three three-phase pins and one ground wire pin. The three three-phase baffle plates are respectively inserted into the three three-phase pins, and the ground wire baffle plate is inserted into the ground wire pin. The through hole of the ground wire baffle plate is provided with a protruding edge.

[0009] The top of the aforementioned mounting post is provided with a protrusion, which presses against the cover plate.

[0010] The number of mounting columns on the aforementioned mounting platform is two.

[0011] The second objective of this utility model is to provide a BLDC motor, including an injection-molded stator, characterized in that: the injection-molded stator is the injection-molded stator described above.

[0012] Compared with the prior art, this utility model has the following advantages:

[0013] 1. The injection-molded stator includes a stator core, an insulating end mounted outside the stator core, a stator coil wound around the insulating end, a cover plate, and an injection-molded body. The injection-molded body encloses the stator core, the insulating end, the stator coil, and the cover plate. The insulating end has several mounting platforms on its end face, each platform having several mounting posts protruding from it. The cover plate includes several cover plates, each cover plate having mounting holes corresponding to the mounting posts. The cover plates are mounted on the mounting platforms, and the mounting posts are inserted into the mounting holes, fixing the cover plates to the insulating end. The cover plates are not limited by the size of the stator core and can be used on stators of different sizes, saving design and production costs. The cover plates are fixed to the insulating end, eliminating the need for ejector pins during injection molding, thus ensuring the insulation of the stator assembly.

[0014] 2. Other advantages of this utility model are described in detail in the embodiments section. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of the injection-molded stator provided in Embodiment 1 of this utility model;

[0016] Figure 2 This is a schematic diagram of the injection-molded stator before injection molding;

[0017] Figure 3 This is a top view of the injection-molded stator before injection molding;

[0018] Figure 4 An exploded view of an injection-molded stator;

[0019] Figure 5 for Figure 4 Enlarged view of point A. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0021] Example 1:

[0022] like Figures 1 to 5 As shown, this embodiment provides an injection-molded stator, including a stator core 1, an insulating end 2 installed outside the stator core 1, a stator coil 3 wound around the insulating end 2, a cover plate, and an injection-molded body 5. The injection-molded body 5 encloses the stator core 1, the insulating end 2, the stator coil 3, and the cover plate. The characteristic feature is that the end face of the insulating end 2 is provided with a plurality of mounting platforms 21, each mounting platform 21 protruding with a plurality of mounting posts 22. The cover plate includes a plurality of cover plates 4, each cover plate 4 having a mounting hole 41 corresponding to the mounting post 22. The cover plate 4 is installed on the mounting platform 21, and the mounting post 22 is inserted into the mounting hole 41 and fixes the cover plate 4 to the insulating end 2.

[0023] The injection-molded stator has a cover plate 4 that is not limited by the size of the stator core 1 and can be used on stators of different sizes, saving design and production costs. The cover plate is fixed on the insulating end 2, so that there is no need to use ejector pins to fix the cover plate 4 during injection molding, thus ensuring the insulation of the stator assembly.

[0024] The aforementioned mounting platform 21 and cover plate 4 are both four in number. The mounting platform 21 has slots 23, and the plurality of mounting posts 22 are located around the slots 23. The cover plate 4 has through holes 42 corresponding to the slots 23. A wire inlet pin 6 is installed in the slot 23. The bottom of the wire inlet pin 6 is connected to the stator coil 3, and the top of the wire inlet pin 6 passes through the through hole 42 and connects to the lead wire 62. The cover plate 4 reinforces the positioning and fixation of the wire inlet pin 6, simplifying the structure of the injection-molded stator.

[0025] The top of the aforementioned inlet pin 6 is provided with a positioning hole 61, one end of the lead wire 62 is inserted into the positioning hole 61, and the other end of the lead wire 62 extends out of the injection molded body 5.

[0026] The four cover plates 4 include three three-phase cover plates 43 and one ground wire cover plate 44. The four inlet pins 6 include three three-phase pins 63 and one ground wire pin 64. The three three-phase cover plates 43 are respectively inserted into the three three-phase pins 63, and the ground wire cover plate 44 is inserted into the ground wire pin 64. The through hole 42 of the ground wire cover plate 44 has a protruding edge 45 around its perimeter. The addition of the protruding edge 45 to the ground wire cover plate 44 makes it easy to distinguish the ground wire cover plate 44 from the three-phase cover plates 43.

[0027] The top of the aforementioned mounting post 22 is provided with a protrusion 24, which presses against the cover plate 4. The protrusion 24 has a simple structure and can effectively fix the cover plate 4.

[0028] The aforementioned protrusion 24 can be made by the following method: Before the cover plate 4 is installed, the diameter of the mounting post 22 of the insulating end 2 is slightly smaller than the diameter of the through hole 41 of the cover plate 4 so that the cover plate 4 can be inserted; after the cover plate 4 is installed on the mounting platform 21, the top of the mounting post 22 protrudes from the cover plate 4, and the top of the mounting post 22 is pressed downward to form the protrusion 24 by welding and riveting process. At this time, the diameter of the protrusion 24 is larger than the diameter of the through hole 41, and the cover plate 4 cannot be removed, thereby fixing the cover plate 4 on the mounting platform 21.

[0029] The number of mounting columns 22 on the aforementioned mounting platform 21 is two.

[0030] Example 2:

[0031] This embodiment provides a BLDC motor, including an injection-molded stator 100, characterized in that: the injection-molded stator 100 is the injection-molded stator described in Embodiment 1.

[0032] The BLDC motor has lower production costs, higher insulation coefficient, and is safer to use.

[0033] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it. Although this utility model 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 of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model.

Claims

1. A molded stator, comprising a stator core (1), an insulating end (2) mounted outside the stator core (1), a stator coil (3) wound around the insulating end (2), a cover plate, and an injection molded body (5), wherein the injection molded body (5) encloses the stator core (1), the insulating end (2), the stator coil (3), and the cover plate, characterized in that: The end face of the insulating end (2) is provided with a plurality of mounting platforms (21), each mounting platform (21) protruding with a plurality of mounting posts (22), the cover plate includes a plurality of cover plates (4), each cover plate (4) is provided with mounting holes (41) corresponding to the mounting posts (22), the cover plate (4) is mounted on the mounting platform (21), the mounting posts (22) are inserted into the mounting holes (41) and the cover plate (4) is fixed on the insulating end (2).

2. The injection-molded stator according to claim 1, characterized in that: The number of the mounting platform (21) and the cover plate (4) are four. The mounting platform (21) is provided with a slot (23). The plurality of mounting posts (22) are located around the slot (23). The cover plate (4) is provided with a through hole (42) corresponding to the slot (23). A wire inlet pin (6) is installed in the slot (23). The bottom of the wire inlet pin (6) is connected to the stator coil (3). The top of the wire inlet pin (6) passes through the through hole (42) and is connected to the lead wire (62).

3. The injection-molded stator according to claim 2, characterized in that: The top of the inlet pin (6) is provided with a positioning hole (61), one end of the lead wire (62) is inserted into the positioning hole (61), and the other end of the lead wire (62) extends out of the injection molded body (5).

4. The injection-molded stator according to claim 3, characterized in that: The four cover plates (4) include three three-phase cover plates (43) and one ground cover plate (44). The four inlet pins (6) include three three-phase pins (63) and one ground pin (64). The three three-phase cover plates (43) are respectively inserted into the three three-phase pins (63), and the ground cover plate (44) is inserted into the ground pin (64). The through hole (42) of the ground cover plate (44) is provided with a protruding edge (45) around it.

5. An injection-molded stator according to any one of claims 1 to 4, characterized in that: The top of the mounting post (22) is provided with a protrusion (24), which presses against the cover plate (4).

6. The injection-molded stator according to claim 5, characterized in that: The number of mounting columns (22) on each mounting platform (21) is two.

7. A BLDC motor, comprising an injection-molded stator (100), characterized in that: The injection-molded stator (100) is the injection-molded stator according to any one of claims 1 to 6.

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