Stator frame and fish-eye terminal pin thereof and brushless motor

Abstract

This utility model relates to the field of motor technology, and in particular to a stator frame, its fisheye connector, and a brushless motor. The stator frame includes a frame body, a horizontal connector integrally injection-molded at its end, a winding section, a wire guide plate, a horizontal wire groove, and a vertical wire inlet groove. The wire groove and the wire inlet groove are located on both sides of the winding section and, together with the wire guide plate, form a regular wiring path for the enameled wire. The fisheye connector adopts a cross-shaped structure, with its tail and short shoulder completely embedded in the frame to enhance fixation. Its fisheye terminal is used for interference fit with the PCB board mounting holes, eliminating the need for soldering. This utility model, through its integrated structural design, simultaneously solves three major technical problems: easy terminal detachment, messy winding of fine wire, and the need for additional soldering processes. It significantly improves the mechanical strength, winding quality, production efficiency, and connection reliability of the stator assembly, and is particularly suitable for high-performance brushless motors produced in automated processes.

Description

Technical Field

[0001] This utility model relates to the field of motor technology, and in particular to a stator frame and its fisheye connector, and a brushless motor. Background Technology

[0002] The electrical connections and winding structure of the stator assembly of a brushless motor directly affect its reliability, production efficiency, and performance. Existing technologies often use an interference fit to press the terminals into a pre-molded frame. This method has limited connection strength, and the axial tensile strength between the terminals and the molded frame is low. Under vibration or insertion / extraction stress, the terminals are prone to loosening or even falling off the frame, affecting the long-term reliability of the motor.

[0003] In the winding process, especially when using fine-diameter enameled wire, the lack of effective guiding and limiting structures leads to irregular and disordered winding, which not only affects the motor's heat dissipation efficiency but also results in low slot fill factor due to loose winding, weakening the motor's magnetic properties. Existing slot structures, such as the lead-out and lead-in slots disclosed in patent CN223156811U, are primarily designed for vertically extending terminals and cannot effectively accommodate horizontally extending pins. If directly applied, the enameled wire easily slips out of the slot under winding tension, failing to achieve stable guidance.

[0004] In addition, traditional terminals need to be soldered to the PCB (printed circuit board) to achieve electrical connection. This soldering process increases production costs and process complexity, and also poses quality risks such as poor soldering and short circuits caused by solder balls.

[0005] Therefore, there is an urgent need in this field for a new type of stator frame structure that can fundamentally solve the problems of insecure terminal fixing, messy winding, and the need for additional welding processes. Utility Model Content

[0006] The technical problem to be solved by this utility model is: in order to solve the problems of poor terminal fixing, messy winding and the need for additional welding process in the prior art mentioned above, a stator frame is provided. Through the synergistic effect of the integrally injection molded terminal pin, the wire groove and the wire inlet groove on both sides and the wire baffle plate, the above-mentioned problems of the prior art are solved, and the overall strength, production efficiency and reliability of the motor stator structure are comprehensively improved.

[0007] The technical solution adopted by this utility model to solve its technical problem is: a stator frame, comprising: A skeleton body, wherein a winding section is provided on the skeleton body; At least one connector pin, which is integrally injection molded with the frame body and disposed at the end of the frame body; A horizontally extending wire groove is formed on the skeleton body and located on one side of the winding part; The vertically extending inlet groove is opened on the skeleton body and is located on the opposite side of the winding part relative to the wire groove. A wire stop plate is installed on the side of the winding section near the path between the wire guide groove and the wire inlet groove.

[0008] The integrated injection-molded connector fundamentally solves the problems of low axial tensile strength and easy detachment of traditional interference fit press-fit terminals, achieving a firm connection between the terminal and the frame. The separate horizontal and vertical wire grooves on both sides of the winding section form a transition path for the enameled wire from the horizontal connector to the vertical winding section, structurally avoiding the risk of irregular winding and easy slippage and detachment caused by the mismatch of wire grooves in the prior art.

[0009] According to one embodiment of the present invention, the groove opening of the wire groove faces the extension direction of the long shoulder on the connector pin, and the height of the groove opening is flush with or lower than the upper end surface of the long shoulder.

[0010] The groove extends towards the long shoulder of the connector and its height is controlled to ensure that the enameled wire can quickly and naturally enter the wire groove after being led out from the long shoulder of the connector, avoiding the wire from being suspended, raised, or bent. This ensures neat winding and reduces the risk of damage to the enameled wire caused by bending stress.

[0011] Furthermore, the bottom of the wire groove slopes downward from its interior towards the groove opening.

[0012] This design allows for more reliable guidance of the enameled wire along a predetermined path during the winding process, preventing it from bouncing or detaching within the groove and effectively solving the problem of loosening when winding fine wire.

[0013] According to one embodiment of the present invention, the depth of the wire groove is greater than or equal to three times the diameter of the enameled wire.

[0014] This design ensures that there is enough space in the groove to accommodate the enameled wire and to cope with normal tension fluctuations during winding, preventing the enameled wire from shifting out of the groove due to insufficient groove depth.

[0015] According to one embodiment of the present invention, the depth of the inlet groove gradually decreases along the direction from the top of the skeleton body toward the winding portion.

[0016] This design smoothly guides the enameled wire from the upper horizontal direction to the lower winding section, avoiding right-angle or acute-angle turns. This makes the transition of the enameled wire's direction more natural, reducing winding resistance and preventing the enameled wire from being pushed open by sharp structures and falling out of the guide groove.

[0017] Furthermore, the bottom of the wire inlet groove includes a flat bottom section and a sloping section connected together. The depth of the flat bottom section is greater than or equal to three times the diameter of the enameled wire, and the angle between the sloping section and the flat bottom section is greater than or equal to 45 degrees.

[0018] The flat bottom section has sufficient depth to stably hold the wire, ensuring that the enameled wire is firmly fixed in its final position before entering the winding section, preventing it from loosening. The beveled section achieves a smooth transition from the flat bottom section to the surface of the frame body. The beveled surface with a specific angle can effectively guide the wire while ensuring that the structure has sufficient strength, avoiding weak points caused by an excessively small angle.

[0019] Furthermore, the position where the flat bottom section and the inclined section intersect is flush with or lower than the upper end surface of the winding section.

[0020] This setup ensures that the enameled wire can be wound quickly and smoothly onto the winding section, achieving a seamless connection between the guiding and winding processes and ensuring a neat starting point for the winding.

[0021] Also provided is a fisheye connector for integral injection molding with the stator frame, comprising: Fisheye terminal section; A long shoulder extends horizontally from one side of the fisheye terminal portion; The short shoulder extends horizontally from the other side of the fisheye terminal portion, and the direction of extension is opposite to that of the long shoulder. The tail extends vertically from the other end of the fisheye terminal portion; The tail and short shoulder are designed to be completely embedded in the plastic material of the skeleton body during injection molding.

[0022] The cross-shaped structure of the fisheye connector, especially the tail and short shoulder which are completely embedded in the injection molded body, can greatly increase the contact area and mechanical interlocking force of the connector within the skeleton, enabling the connector to withstand greater axial tension and torque, thus solving the problem of easy terminal detachment in the prior art.

[0023] Furthermore, the cross-sectional shape of the fisheye terminal portion can be interference-fitted with the mounting holes of the PCB board.

[0024] This setup not only eliminates the soldering step, reducing costs and process complexity, but also avoids quality issues such as cold solder joints and solder balls, achieving a fast and reliable conductive connection, making it suitable for automated assembly.

[0025] A brushless motor is provided, including the stator frame described in the above solution.

[0026] The beneficial effects of this utility model are: By designing the connector pin and the frame as an integral injection molding, and making the tail and short shoulder of the connector pin completely embedded in the plastic material of the frame, a robust mechanical interlocking structure is formed. This overcomes the defect of low axial tensile strength of traditional interference fit press-fit terminals, effectively resists vibration and insertion / extraction stress, eliminates the risk of terminals loosening or falling off during long-term use, and greatly improves the structural reliability and service life of the motor stator assembly. By setting horizontally extending wire grooves and vertically extending wire inlet grooves on both sides of the winding section, and limiting them with wire baffles, a precise and smooth wire path is formed between the horizontal connecting pin and the vertical winding section for the enameled wire. This effectively prevents the thin-diameter enameled wire from becoming loose, slipping, or irregularly arranged during the winding process, ensuring tight and neat winding, thereby optimizing the magnetic performance and output efficiency of the motor, and also improving the heat dissipation conditions of the winding.

[0027] By setting the terminal part of the connector pin to a fisheye shape, it can directly achieve an interference fit with the mounting hole of the PCB board. This extrusion stress generated by elastic deformation ensures the reliability of conductivity, thereby completely eliminating the soldering process required in traditional processes. This not only saves solder material costs, simplifies the production process, and improves assembly efficiency, but also eliminates quality risks such as cold solder joints and short circuits caused by soldering operations, thus improving product consistency. Attached Figure Description

[0028] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0029] Figure 1 This is a schematic diagram of the stator frame of this utility model.

[0030] Figure 2 yes Figure 1 A schematic diagram of the structure at the center connector pin.

[0031] Figure 3 This is a schematic diagram of the stator frame winding process of this utility model.

[0032] Figure 4 This is a schematic diagram of the stator frame after winding according to this utility model.

[0033] Figure 5 This is a schematic diagram of the installation of the wiring pins on the stator frame and the PCB board of this utility model.

[0034] Figure 6 This is a schematic diagram of the structure of the fisheye connector of this utility model.

[0035] In the diagram: 1. Frame body; 11. Winding section; 2. Connecting pin; 21. Long shoulder; 22. Fisheye terminal; 23. Tail; 24. Short shoulder; 3. Wire baffle; 4. Wire groove; 41. Groove opening; 5. Wire inlet groove; 51. Flat bottom section; 52. Angled section; 6. PCB board; 61. Mounting hole; 7. Enamelled wire. Detailed Implementation

[0036] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, illustrating only the basic structure of the present invention, and therefore only show the components relevant to the present invention.

[0037] Example 1 like Figure 1 and Figure 2 As shown, a stator frame includes a plastic frame body 1. On the frame body 1, a winding part 11 for winding enameled wire 7 is provided. At least one metal connector 2 is integrally formed with the frame body 1 during the injection molding stage and is horizontally set at the end of the frame body 1. This integral injection molding process makes the connector 2 and the frame body 1 combined into a solid whole.

[0038] Specifically, the skeleton body 1 is formed by pressure injection molding of engineering plastic using a precision mold. During the injection molding process, the pre-stamped metal connector 2 is placed into the mold cavity, so that it combines with the molten plastic to form an integrated structure.

[0039] Two key wire grooves are designed on the skeleton body 1: a horizontally extending wire groove 4, which is formed on the skeleton body 1 and located on one side of the winding section 11; and a vertically extending inlet groove 5, which is formed on the skeleton body 1 and located on the opposite side of the winding section 11 opposite to the wire groove 4. On the side of the winding section 11 near the path between the wire groove 4 and the inlet groove 5, a wire baffle 3 is protruded to limit the displacement of the enameled wire 7 in this transition area.

[0040] like Figure 2 As shown, the opening 41 of the wire groove 4 faces the extension direction of the long shoulder 21 on the connector 2, and the height of the opening 41 is not higher than the upper end face of the long shoulder 21, which allows the enameled wire 7 wound from the long shoulder 21 to smoothly enter the wire groove 4. The bottom of the wire groove 4 slopes downward from its interior towards the opening 41, forming a natural guide slope, and the depth of the wire groove 4 is not less than 3 times the diameter of the enameled wire 7 to ensure sufficient space to accommodate the enameled wire.

[0041] The depth of the inlet groove 5 gradually decreases from the top of the skeleton body 1 toward the winding section 11. The bottom of the groove includes a connected flat-bottom section 51 and a sloping section 52. The depth of the flat-bottom section 51 is not less than three times the diameter of the enameled wire 7 to provide a stable wire-holding area. The angle between the sloping section 52 and the flat-bottom section 51 is not less than 45 degrees, forming a smooth transition. The intersection of the flat-bottom section 51 and the sloping section 52 is not higher than the upper surface of the winding section 11, ensuring that the enameled wire 7 can smoothly begin to wind onto the winding section 11.

[0042] The winding process in this embodiment is as follows: Figure 3 and Figure 4 As shown: First, the end of the enameled wire 7 is tightly wound 6 to 10 times on the long shoulder 21 of the connector 2, which serves as the wire inlet, and is initially fixed by the contraction at its end. Then, the winding machine guides the enameled wire 7 away from the long shoulder 21, so that it is embedded in the wire groove 4. Under the guidance of the inclined surface of the groove bottom and the restriction of the wire baffle 3, the enameled wire 7 moves horizontally to the upper end surface of the skeleton body 1 while closely following the bottom of the groove. Next, the enameled wire 7 descends from the upper end face, first falling into the flat bottom section 51 of the wire inlet groove 5, where it is stably constrained, and then smoothly enters the winding section 11 along the inclined section 52. Finally, after the enameled wire 7 is led out from the wire inlet groove 5, it begins to be wound in multiple layers on the main winding section 11. The winding equipment arranges the wires according to the preset program to ensure that the winding is tight and neat; after the winding is completed, the end of the enameled wire 7 is wound out from the connector 2, which serves as the wire outlet, and is fixed close to the inner side of the frame body 1 near that end.

[0043] like Figure 5 As shown, after winding is completed, the fisheye terminal portion 22 of the stator frame is aligned with the mounting hole 61 on the PCB board 6 and inserted, and appropriate pressure is applied to insert it. During the insertion process, the arc-shaped structure of the fisheye terminal portion 22 undergoes elastic deformation, generating continuous radial compressive stress on the inner wall of the mounting hole 61. This interference fit connection method based on structural elastic deformation is similar to the connection method between fisheye terminals and circuit boards in the prior art, such as the interference fit connection between fisheye terminals and PCBs disclosed in Chinese Patent No. CN218771653U. They all aim to achieve solderless connection. This interference fit in this embodiment ensures an electrical connection with extremely low contact resistance and stable conductivity, completely replacing the traditional soldering process. At the same time, the symmetrically distributed pins ensure uniform force when connected to the PCB board 6, avoiding warping of the PCB board 6 caused by unilateral stress.

[0044] Example 2 like Figure 6As shown, a fisheye connector is made of phosphor bronze with a nickel-plated surface to ensure good conductivity and corrosion resistance. It has a cross-shaped structure, including a fisheye terminal 22, a long shoulder 21, a tail 23, and a short shoulder 24. The fisheye terminal 22 is a symmetrical arc-shaped structure resembling a fisheye, with an elongated oval opening in its center corresponding to the outer arc shape, ensuring good elasticity. The long shoulder 21 extends horizontally from one side of the fisheye terminal 22 (X direction in the figure), and its end has a narrowing in the width direction (Z direction in the figure) to facilitate initial wire winding fixation and subsequent possible welding reinforcement. The short shoulder 24 is located on the other side of the fisheye terminal 22, extending in the opposite direction to the long shoulder 21. The tail 23 extends vertically from the other end of the fisheye terminal 22 (Y direction in the figure). After injection molding, the tail 23 and short shoulder 24 are completely encapsulated and embedded within the plastic material of the skeleton body 1, forming a strong mechanical interlock.

[0045] In this embodiment, the connector pin 2 adopts a cross-shaped structure with two embedded parts, which greatly increases the contact area and bonding force between the connector pin 2 and the skeleton body 1, enabling it to withstand greater axial tensile force and fundamentally solving the problem of easy terminal detachment.

[0046] Example 3 A brushless motor includes a stator frame as described in Embodiment 1. The stator frame of Embodiment 1 solves the problems of terminal fixing, winding guidance and electrical connection through the synergistic effect of an integrally injection-molded cross-shaped fisheye connector 2, a wire groove 4 and a wire inlet groove 5 located on both sides and a wire baffle plate 3. Therefore, it is particularly suitable for small brushless motors with high requirements for reliability and production efficiency.

[0047] Based on the above-described preferred embodiments of this utility model, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the technical concept of this utility model. The technical scope of this utility model is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A stator frame, characterized in that, include: The skeleton body (1) is provided with a winding part (11). At least one connector (2), the connector (2) is integrally injection molded with the skeleton body (1) and is disposed at the end of the skeleton body (1); A horizontally extending wire groove (4) is opened on the skeleton body (1) and located on one side of the winding part (11); The vertically extending inlet groove (5) is opened on the skeleton body (1) and is located on the other side of the winding part (11) opposite to the wire groove (4); The wire baffle (3) is located on one side of the winding section (11) near the path between the wire guide groove (4) and the wire inlet groove (5).

2. The stator frame according to claim 1, characterized in that: The groove of the wire groove (4) faces the extension direction of the long shoulder (21) on the connector (2), and the height of the groove (41) is flush with or lower than the upper end face of the long shoulder (21).

3. The stator frame according to claim 1 or 2, characterized in that: The bottom of the wire groove (4) slopes downward from its interior toward the groove opening (41).

4. The stator frame according to claim 1, characterized in that: The depth of the wire groove (4) is greater than or equal to three times the diameter of the enameled wire.

5. The stator frame according to claim 1, characterized in that: The depth of the inlet groove (5) gradually decreases from the top of the skeleton body (1) toward the winding part (11).

6. The stator frame according to claim 5, characterized in that: The bottom of the inlet groove (5) includes a flat bottom section (51) and a slope section (52) connected together. The depth of the flat bottom section (51) is greater than or equal to 3 times the diameter of the enameled wire, and the angle between the slope section (52) and the flat bottom section (51) is greater than or equal to 45 degrees.

7. The stator frame according to claim 6, characterized in that: The position where the flat bottom section (51) and the inclined section (52) intersect is flush with or lower than the upper end surface of the winding part (11).

8. A fisheye connector pin, used for integral injection molding with a stator frame, characterized in that, include: Fisheye terminal (22); The long shoulder (21) extends horizontally from one side of the fisheye terminal portion (22); The short shoulder (24) extends horizontally from the other side of the fisheye terminal portion (22), and the direction of extension is opposite to that of the long shoulder (21); The tail (23) extends vertically from the other end of the fish-eye terminal portion (22); The tail (23) and short shoulder (24) are used to be completely embedded in the plastic material of the skeleton body (1) during injection molding.

9. The fisheye connector pin according to claim 8, characterized in that, The cross-sectional shape of the fisheye terminal (22) can be interference-fitted with the mounting hole (61) of the PCB board (6).

10. A brushless motor, characterized in that: Includes the stator frame as described in any one of claims 1 to 7.

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