Electric pump

Abstract

An electric pump (100) comprising a stator winding (131), a housing (134), and a pump shaft (133), wherein the housing (134) comprises a first housing (1341) and a second housing (1342), at least a portion of the first housing (1341) is formed to be injection molded with the stator winding (131) as an insert, a first unit (136) is defined to include the first housing (1341) and the stator winding (131), at least a portion of the second housing (1342) is formed to be injection molded with the first unit (136) and the pump shaft (133) as inserts, the first housing (1341) includes a first parting surface (A), and the second housing (1342) includes a second parting surface (B), the first parting surface (A) and the second parting surface (B) are on the same plane. This structure allows for a reduction in the tolerance for coaxiality between the pump shaft and the stator windings.

Description

Technical Field

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[0003]

[0001] This application claims the priority of two Chinese patent applications, one filed with the China National Patent Office on March 28, 2023, with an application number of 202310333278.X and an invention title of "Electric Pump", and the other filed with the China National Patent Office on March 28, 2023, with an application number of 202310348826.6 and an invention title of "Method for Manufacturing an Electric Pump", and all of its content is incorporated herein by reference.

[0002] The present invention relates to a fluid pump, particularly an electric pump.

Background Art

[0003] An electric pump includes a stator winding, a pump shaft, and a housing. The housing is an injection molded body, and the stator winding and the pump shaft are formed by at least two injection moldings with the stator winding and the pump shaft as inserts. In the multiple injection molding processes, the stator winding and the pump shaft as inserts may be located in different injection molding operation steps. Therefore, reducing the coaxiality tolerance between the pump shaft and the stator winding is a technical problem that needs to be considered by those skilled in the art.

Summary of the Invention

Problems to be Solved by the Invention

[0004] The object of the present invention is to provide an electric pump capable of reducing the coaxiality tolerance between the pump shaft and the stator winding.

Means for Solving the Problems

[0005] To achieve the above object, the present invention An electric pump comprising a stator winding, a housing, and a pump shaft, wherein the housing comprises a first housing and a second housing, at least a portion of the first housing being formed to be injection molded with the stator winding as an insert, the first unit being defined to include the first housing and the stator winding, and at least a portion of the second housing being formed to be injection molded with the first unit and the pump shaft as inserts, the first housing comprising a first parting surface, the second housing comprising a second parting surface, and the first and second parting surfaces being on the same plane.

[0006] Furthermore, in the present invention, the parting surfaces of at least a portion of the first housing formed with the stator windings as inserts and at least a portion of the second housing formed with the first unit and pump shaft as inserts are on the same plane, the first unit can proceed to the next injection molding step without being demolded from a portion of the injection molding die, and positioning errors due to repeated clamping between the first unit and the injection molding die can be reduced, thereby reducing the tolerance for coaxiality between the pump shaft and the stator windings. [Brief explanation of the drawing]

[0007] [Figure 1] This is a three-dimensional view of an electric pump, which is a first embodiment of the present invention. [Figure 2] Figure 1 is an exploded view of the electric pump. [Figure 3] This diagram shows the XX cross-section of the electric pump in Figure 1. [Figure 4] Figure 1 is a three-dimensional view of the stator windings of the electric pump. [Figure 5] Figure 1 is a three-dimensional view of the stator unit of the electric pump. [Figure 6] Figure 5 is an exploded view of the stator unit. [Figure 7] This is a cross-sectional view of the stator unit along the YY direction in Figure 5. [Figure 8] This is a three-dimensional view of the first unit from one direction. [Figure 9] This is a cross-sectional view of the first unit along the ZZ line in Figure 8. [Figure 10] This is a three-dimensional view of the second housing in Figure 5. [Figure 11] This is a cross-sectional view of the second housing in one direction in Figure 10. [Figure 12] Figure 5 is a three-dimensional view of the connecting plate unit assembled onto the stator winding. [Figure 13] This is a three-dimensional view of the connecting plate unit (with the connector removed) in Figure 12. [Figure 14] Figure 12 is a cross-sectional view of another embodiment of the connecting plate unit. [Figure 15] Figure 14 is a three-dimensional view showing the main body fitted into the position limiting member. [Figure 16] Figure 14 is a three-dimensional view of one embodiment in which a portion of the pin portion is fitted into the connector. [Figure 17] Figure 14 is a three-dimensional view of another embodiment in which a portion of the pin portion is fitted into the connector. [Figure 18] This is a cross-sectional view of an embodiment in which the stator winding and connecting plate unit are arranged as inserts in the first jig. [Figure 19] This is a cross-sectional view of an embodiment after a portion of the mold of the first jig and the second jig have been clamped together. [Modes for carrying out the invention]

[0008] The present invention will be further described below with reference to the drawings and embodiments.

[0009] Embodiments of the present invention will be further described below with reference to the drawings. First, the directional terms such as top, bottom, left, right, front, back, inside, outside, ceiling, and bottom, as mentioned or referable in the specification of this invention, are defined to correspond to the structure in the drawings and are relative concepts, and therefore may change accordingly depending on different locations and different usage conditions. Therefore, these or other directional terms should not be construed as limiting terms.

[0010] The electric pump in the following embodiments can provide flow power to the working medium of the vehicle thermal management system. The working medium may be an aqueous solution containing 50% ethylene glycol or fresh water, or other substances.

[0011] As shown in FIGS. 1 to 8, the electric pump 100 of the present invention includes a pump cover 11, a rotating unit 12, and a stator unit 13. The stator unit 13 includes a connection plate unit 132, a stator winding 131, a pump shaft 133, and a housing 134. The pump cover 11 and the stator unit 13 are hermetically fixed. Here, the hermetic fixation prevents the working medium from leaking outside the electric pump 100 when the electric pump 100 operates. The pump shaft 133 and the housing 134 are injection-molded and fixed. Here, a part of the pump shaft 133 is fitted into the housing 134. The electric pump 100 has a pump cavity 20. The rotating unit 12 is located in the pump cavity 20. The pump cavity 20 includes a communicating rotor cavity 141 and a blade cavity 15. The rotating unit 12 includes a rotor unit 122 and a blade unit 121. The rotor unit 122 includes permanent magnets. Furthermore, at least a part of the rotor unit 122 is located in the rotor cavity 141. The blade unit 121 is located in the blade cavity 15. The working medium flows in the pump cavity 20. At least a part of the other end of the pump shaft 133 is located in the rotor cavity 141. At least a part of the rotating unit 12 is externally fitted on the outer periphery of the pump shaft 133. The rotating unit 12 and the pump shaft 133 are connected so as to transmit power. In another embodiment, the rotating unit 12 and the pump shaft 133 are fixedly connected, and the pump shaft 133 rotates with the rotor unit 122. The connection board unit 132 includes a position limiting member 1321 and a conductive member 1322. And this position limiting member 1321 is connected or fixedly connected so as to be position-limited by the stator winding 131, and the conductive member 1322 is connected or fixedly connected so as to be position-limited by the position limiting member 1321. Specifically, a part of the conductive member 1322 is fitted into the position limiting member 1321, and the position limiting member 1321 is an injection molded member. The conductive member 1322 includes a first connection end and a second connection end. The first connection end is electrically connected to the stator winding 131, and the second connection end can function as a pin end when electrically connected to an external power source of the electric pump 100. As another implementation form, the electric pump 100 may not include the pump cover 11, and the pump cover 11 is integrated into an external structure. Arranged in this way, it is more advantageous for the integrated design of the electric pump 100. The structure of the electric pump 100 becomes more compact, which is more advantageous for the miniaturization and weight reduction of the structure of the electric pump 100. When the electric pump 100 operates, by controlling the current of the stator winding 131, further, the excitation magnetic field generated from the stator winding 131 is controlled, and under the action of the excitation magnetic field, the rotating unit 12 rotates around the pump shaft 133.

[0012] As shown in FIG. 4, the stator winding 131 includes a stator core 1311, an insulating frame 1312, and a winding 1313. And the number of the windings 1313 is at least three. The insulating frame 1312 covers at least a part of the surface of the stator core 1311, and the insulating frame 1312 isolates the winding 1313 and the stator core 1311 to electrically insulate them. The insulating frame 1312 and the stator core 1311 may be an integral structural part. Specifically, the insulating frame 1312 is formed by injection molding with the stator core 1311 as an insert. In another embodiment, the insulating frame 1312 and the stator core 1311 are arranged separately, where “separate arrangement” means that the insulating frame 1312 and the stator core 1311 are processed as two separate parts and then assembled. It is connected in a position-restricted manner or fixed in place so that it can be attached. In this embodiment, the insulating frame 1312 is formed by injection molding with the stator core 1311 as an insert. Here, the stator core 1311 and the insulating frame 1312 are integrated into a single structure. The winding 1313 is wrapped around the insulating frame 1312. In a specific embodiment, the winding 1313 includes nine windings, and in other embodiments, the winding 1313 may include other numbers of windings, such as three, six, or twelve.

[0013] As shown in Figures 1 to 13, the housing 134 includes a first housing 1341 and a second housing 1342, the first housing 1341 being formed to be injection molded with at least the stator windings 131 as inserts. Furthermore, at least a portion of the first housing 1341 is formed to be injection-molded with the stator windings 131 as inserts, and in other embodiments, the first housing 1341 is formed to be injection-molded with the connecting plate unit 132 and the stator windings 131 as inserts, and the form in which the first housing 1341 is injection-molded with the connecting plate unit 132 and the stator windings 131 as inserts is not described in detail here, but should be specifically referred to below. The first unit 136 is defined to include a first housing 1341 and a stator winding 131, and at least a portion of the second housing 1342 is formed to be injection molded with the first unit 136 and the pump shaft 133 as inserts, specifically the second housing 1342 is formed to be injection molded with the first unit 136 and the pump shaft 133 as inserts, the first housing 1341 and the second housing 1342 are injection molded and fixed together, the first housing 1341 includes a first parting surface A, and the second housing 1342 includes a second parting surface B, the first parting surface A and the second parting surface B are on the same plane. To facilitate subsequent descriptions, the injection molding of the stator winding 131 and connecting plate unit 132 as inserts is defined as the first injection molding, and the injection molding of the first unit 136 and pump shaft 133 as inserts is defined as the second injection molding. Thus, the first unit 136, formed with at least the stator winding 131 as an insert, can proceed to the next injection molding step without being demolded from a part of the injection molding die. In the next injection molding step, at least the first unit 136 and the pump shaft 133 are injection molded as inserts. Since the first parting surface A and the second parting surface B are on the same plane, the first unit 136, formed with at least the stator winding 131 as an insert, does not demold from a part of the injection molding die. This reduces positioning errors due to repeated clamping between the first unit 136 (which is the insert) and the injection molding die, thereby reducing the coaxial accuracy between the pump shaft 133 and the stator winding 131. As shown in Figures 18 and 19, the injection molding die is defined to include a first mold C. During the first injection molding, the die used is the first mold C. After the first injection molding is completed, a portion of the first mold is demolded, and the first unit 136 is located in the first mold C. During the second injection molding, a portion of the first mold C and the second mold D work together to complete the second injection molding. Thus, during the second injection molding, the positioning criteria for inserting at least the pump shaft 133 is the same as the positioning criteria for the first injection molding, reducing positioning errors due to repeated clamping between the first unit 136, which is the insert, and the injection molding die, and further reducing the tolerance for coaxiality between the pump shaft 133 and the stator core 1311.

[0014] As shown in Figures 1 to 9, along the axial direction of the electric pump 100, the connecting plate unit 132 is positioned or fixed and connected to the stator winding 131 so as to be restricted in position, the connecting plate unit 132 is electrically connected to the winding 1313 of the stator winding 131, and at least a portion of the first housing 1341 is formed to be injection molded with the stator winding 131 and the connecting plate unit 132 as inserts, and at least a portion of the connecting plate unit 132 and a portion of the stator winding 131 are located inside the first housing 1341. In this way, the electric pump 100 can be made smaller in the radial direction, and the assembly process of the electric pump 100 can be simplified by injection molding the connecting plate unit 132 and the stator winding 131 as inserts.

[0015] As shown in Figures 4 to 9, the first unit 136 comprises a first cavity 1362, and the wall portion corresponding to the first cavity 1362 includes a bottom portion 1362a and a side portion 1362b. The bottom portion 1362a is provided at one end of the side portion 1362b, and the second housing 1342 includes a rotor cavity bottom portion 1411 and a rotor cavity side portion 1412, the rotor cavity bottom portion 1411 and the rotor cavity side portion 1412 are sealed and connected so as to be injection molded, the rotor cavity bottom portion 1411 is located above the bottom portion 1362a of the first cavity 1362 and is positioned to contact the bottom portion 1362a of the first cavity 1362, and the wall portion corresponding to the rotor cavity 141 includes the rotor cavity bottom portion 1411 and the rotor cavity side portion 1412. Furthermore, in the radial direction of the electric pump 100, the rotor cavity bottom 1411 covers the bottom 1362a of the first cavity 1362, and the rotor cavity side 1412 is located radially inward of the side 1362b of the first cavity 1362 and is provided to contact the side 1362b of the first cavity 1362, and along the circumferential direction of the side 1362b of the first cavity 1362, the rotor cavity side 1412 covers the side 1362b of the first cavity 1362. In this way, when the electric pump 100 is operating, a working medium flows through the rotor cavity 141, and during the second injection molding, the rotor cavity bottom 1411 and the rotor cavity side 1412 are formed simultaneously, and the rotor cavity bottom 1411 and the rotor cavity side 1412 are sealed and fixed together. Since the rotor cavity bottom 1411 and the rotor cavity side 1412 are molded in different injection molding steps, the joint surface between the rotor cavity bottom 1411 and the rotor cavity side 1412 is reduced, and the risk of the working fluid in the rotor cavity 141 leaking from the joint surface between the rotor cavity bottom 1411 and the rotor cavity side 1412 during operation of the electric pump 100 is reduced, thereby extending the operating life of the electric pump 100.

[0016] As shown in Figures 1 to 9, the pump shaft 133 and the second housing 1342 are injection molded and fixed together, and to reduce the risk of the working fluid in the rotor cavity 141 leaking from the joint surface between the pump shaft 133 and the second housing 1342, the pump shaft 133 includes a fixed portion 1331 and a rotating portion 1332. The fixed portion 1311 is injection molded and fixed to the rotor cavity bottom 1411, fitted into the rotor cavity bottom 1411, with at least a portion of the rotating portion 1332 located in the rotor cavity 141, the end of the fixed portion 1331 located in the rotor cavity bottom 1411, and a portion of the rotor cavity bottom 1411 encloses the end of the fixed portion 1331. In this way, the end of the pump shaft 133 is enclosed within the rotor cavity bottom 1411, where the end of the pump shaft 133 is not exposed from the lower end surface of the rotor cavity bottom 1411, thus reducing the risk of leakage from the joint surface between the pump shaft 133 and the second housing 1342.

[0017] As shown in Figures 1 to 9, the second housing 1342 further includes a radially extending segment 1342a, which is sealed and connected to one end of the rotor cavity side portion 1412, and along the axial direction of the electric pump 100, the radially extending segment 1342a is injection molded and fixed to the end of the first unit 136, away from the bottom portion 1362a relative to the rotor cavity bottom portion 1411, and the electric pump 100 includes a communicating blade cavity 15 and a rotor cavity 141, the wall portion corresponding to the rotor cavity 141 includes the rotor cavity bottom portion 1411 and the rotor cavity side portion 1412, and the wall portion corresponding to the blade cavity 15 includes at least a portion of the radially extending segment 1342a. Thus, when the electric pump 100 is operating, a working medium is present in the rotor cavity 141 and the blade cavity 15. During the second injection molding, the wall surface corresponding to the rotor cavity 141 and the wall surface corresponding to the blade cavity 15 are formed simultaneously. With respect to the radially extending segment 1342a and the wall surface corresponding to the rotor cavity, the rotor cavity bottom 1411 and the rotor cavity side 1412 are not located in the same injection molding step. This reduces the direct contact surface between the radially extending segment 1342a and the rotor cavity side 1412, and further reduces the risk of the working medium present in the rotor cavity 141 and the blade cavity 15 leaking from the contact surface.

[0018] As shown in Figures 7 to 9, the inner wall surface of the side portion 1362b may include only the inner wall surface of the first housing 1341. When the inner wall surface of the side portion 1362b covers the inner wall surface of the stator core 1311 during the first injection molding, the thickness of the rotor cavity side portion 1412 is reduced when the rotor cavity side portion 1412 is provided on the inner wall surface of the side portion 1362b during the second injection molding to ensure a small magnetic air gap between the stator core 1311 and the rotor unit 122. To increase the thickness of the rotor cavity side portion 1412 and improve its strength, the inner wall surface of the side portion 1362b includes the inner wall surface of the stator core 1311 and the inner wall surface of the first housing 1341. Specifically, the first unit 136 includes a positioning section. Furthermore, this positioning portion 1311c includes a support portion and a position limiting portion, the support portion being located at the end of the stator core 1311 and the position limiting portion being located on the outer circumferential side of the stator core 1311. During the first injection molding process, the support section and the position limiting section work together to serve as the positioning reference for the injection molding. The first housing 1341 positions the parts other than the positioning portion 1311c and the inner wall surface of the stator core 1311 within the first main body portion 1341a, thereby isolating the parts other than the positioning portion 1311c and the inner wall surface of the stator core 1311 from the air. In this way, a small magnetic air gap between the stator core 1311 and the rotor unit can be guaranteed, and the strength of the rotor cavity side portion 1412 can be improved.

[0019] As shown in Figures 3 to 9, the first housing 1341 includes a first main body portion 1341a and a first edge portion 1341b. The first main body portion 1341a is formed by injection molding with the stator winding 131 as an insert, and at least a portion of the stator winding 131 is located within the first main body portion 1341a, the stator winding 131 includes a stator core 1311, the stator core 1311 includes a first end portion 1311a and a second end portion 1311b, the first edge portion 1341b is provided radially outward of the first main body portion 1341a, and here and below, "radially outward" is in a direction perpendicular to the axial direction of the electric pump and away from the axis of the electric pump 100. The first edge portion 1341b approaches the first end portion 1311a, and specifically, the first edge portion 1341b is arranged along the circumferential direction of the first main body portion 1341a. The first edge portion 1341b may be formed during the first injection molding or during the second injection molding. As described above, the first edge portion 1341b in this embodiment is formed during the first injection molding. The first edge portion 1341b is located between the first end portion 1311a and the second end portion 1311b, along a direction parallel to the axial direction of the electric pump 100. Specifically, the first end portion 1311a is separated from the connecting plate unit 132 relative to the second end portion 1311b, and the first edge portion 1341b is provided at one end of the first main body portion 1341a. Specifically, the winding 1313 is located within the first main body 1341a, where the first main body 1341a isolates the winding 1313 from the air. A portion of the stator core 1311 and at least a portion of the insulating frame 1312 are located within the first main body 1341a, where the first main body 1341a isolates the portion of the stator core 1311 and at least a portion of the insulating frame 1312 from the air. With this arrangement, the first edge portion 1341b can function as a support for connecting the electric pump 100 to the external structure. When selecting fasteners for connecting to the external structure, this arrangement reduces the length of the fasteners, ensuring the connection strength between the electric pump 100 and the external structure, while also reducing manufacturing costs.

[0020] As shown in Figures 3 to 9, the first edge portion 1341b includes a first end face 1341c and a second end face 1341d. Along the direction parallel to the electric pump 100, the first end face 1341c approaches the first end portion 1311a relative to the second end face 1341d, and here, the first end face 1341c approaches the positioning portion 1311c relative to the second end face 1341d. The surface on which the first parting surface A or the second parting surface B is located is defined as the first reference surface 101, and the first reference surface 101 and the surface on which the second end surface 1341d is located are on the same surface. In this way, the first reference surface 101 and the second end surface 1341d are located on the same plane, providing a certain foundation for multiple possible structures of the second housing 1342. Here, the first reference surface 101 is provided at this location, and the structure of the second housing 1342 encloses at least a portion of the first edge portion 1341b, thereby improving the joint strength between the first housing 1341 and the second housing 1342.

[0021] As another implementation, as shown in Figures 3 to 9, the first edge portion 1341a includes a first end face 1341c and a second end face 1341d. Furthermore, along the axial direction of the electric pump 100, the second end face 1341d approaches the second end 1311b relative to the first end face 1341c, and the surface on which the first parting surface A or the second parting surface B is located is defined as the first reference surface 101', and the first reference surface 101' is located between the surface on which the second end face 1341d is located and the plane on which the first end face 1341c is located, or the first reference surface 101' and the surface on which the first end face 1341c is located are on the same plane. In this way, a certain foundation can be laid for multiple structural possibilities of the second housing 1342. Here, depending on the different selection of the first reference plane 101' / 101, the structural design of the second housing 1342 can be appropriately modified, and a certain foundation can be laid for multiple suitable structures of the second housing 1342.

[0022] To further reduce the manufacturing cost of the electric pump 100, different injection molding materials may be selected for the first housing 1341 and the second housing 1342, as shown in Figures 1 to 19. Specifically, the hydrolysis resistance of the material for the first housing 1341 is lower than that of polyphenylene sulfide (PPS), while the hydrolysis resistance of the material for the second housing 1342 is higher than that of polyphenylene sulfide. Specifically, the material of the first housing 1341 includes, but is not limited to, thermoplastic polyester material, and specifically, the material of the first housing 1341 includes polybutylene terephthalate (PBT), and the material of the second housing 1342 includes, but is not limited to, thermoplastic resin material, and specifically, for the material of the second housing 1342, a material that has hydrolysis resistance, heat resistance, is weldable, has low dimensional shrinkage and low hygroscopicity may be selected, and specifically, the second housing 1342 includes polyphenylene sulfide (PPS). In this way, the manufacturing cost of the electric pump 100 can be reduced, and the service life of the electric pump 100 can be extended.

[0023] As shown in Figures 1 to 19, the second housing 1342 includes a first sealing portion, and the pump cover 11 includes a second sealing portion. The first and second sealed sections are sealed and fixed together, with fixing methods including welding and bonding. The welding methods include laser welding, friction welding, and ultrasonic welding, which are not described in detail here.

[0024] As shown in Figures 3 to 11, at least a portion of the first housing 1341 is formed to be injection molded with the stator windings 131 as an insert, or here, the first housing 1341 is formed to be injection molded with at least the stator windings 131 as an insert, the first unit 136 is defined to include the first housing 1341 and the stator windings 131, and at least a portion of the second housing 1342 is formed to be injection molded with the first unit 136 and the pump shaft 133 as an insert, or here, the second housing 1342 is formed to be injection molded with at least the first unit 136 and the pump shaft 133 as an insert, the first housing 1341 and the second housing 1342 are injection molded and fixed together, and the second housing 1342 includes a cylindrical portion 1342b and a radially extending segment 1342a. Furthermore, this cylindrical portion 1342b includes a rotor cavity bottom portion 1411 and a rotor cavity side portion 1412, and the wall portion corresponding to the rotor cavity 141 includes the rotor cavity bottom portion 1411 and the rotor cavity side portion 1412. Furthermore, along the radial direction of the electric pump 100, the radially extending segment 1342a is provided on the radially outer side of the cylindrical portion 1342b. Specifically, the wall portion corresponding to the rotor cavity 141 includes the radially extending segment 1342a. The electric pump 100 is equipped with a pump cavity 20, and when the electric pump 100 is operating, a working medium can flow through the pump cavity 20. The wall portion corresponding to the pump cavity 20 includes the cylindrical portion 1342b and the radially extending segment 1342a. The material of the first housing 1341 is different from the material of the second housing 1342. In this way, when the electric pump 100 is operating, the requirements for the material performance level of the first housing 1341, such as the hydrolysis resistance level, can be reduced, and the manufacturing cost of the electric pump 100 can be reduced. Furthermore, when the electric pump 100 is operating, a working medium is present in the rotor cavity 141 and the blade cavity 15, and during the second injection molding, the wall surface corresponding to the rotor cavity 141 and the wall surface corresponding to the blade cavity 15 are formed simultaneously. With respect to the radially extending segment 1342a and the wall surface corresponding to the rotor cavity 141, the rotor cavity bottom 1411 and the rotor cavity side 1412 are not located in the same injection molding step, thereby reducing the direct contact surface between the radially extending segment 1342a and the rotor cavity side 1412, and further reducing the risk of the working fluid present in the rotor cavity 141 and blade cavity 15 leaking from the aforementioned contact surface.

[0025] As shown in Figures 3 to 11, the first unit 136 comprises a first cavity 1362, the wall portion corresponding to the first cavity 1362 includes a bottom portion 1362a and a side portion 1362b, the bottom portion 1362a is provided at one end of the side portion 1362b, and the second housing 1342 includes a rotor cavity bottom portion 1411 and a rotor cavity side portion 1412. The rotor cavity bottom 1411 and the rotor cavity side 1412 are sealed and connected so as to be injection molded, and the rotor cavity bottom 1411 is positioned above the bottom 1362a of the first cavity 1362 and is positioned to contact the bottom 1362a of the first cavity 1362, and the wall portion corresponding to the rotor cavity 141 includes the rotor cavity bottom 1411 and the rotor cavity side 1412. In the radial direction of the electric pump 100, the rotor cavity bottom 1411 covers the bottom 1362a of the first cavity 1362, and the rotor cavity side 1412 is positioned radially inward of the side 1362b of the first cavity 1362 and is arranged to contact the side 1362b of the first cavity 1362. Along the circumferential direction of the side 1362b of the first cavity 1362, the rotor cavity side 1412 covers the side 1362b of the first cavity 1362. Thus, the housing 134 is formed by at least two injection molding processes, improving the appearance quality of the wall portion corresponding to the rotor cavity 141, for example, the cylindricity of the wall portion corresponding to the rotor cavity, and further improving the efficiency of the electric pump 100.

[0026] As shown in Figures 1 to 11, the second housing 1342 includes a first sealing portion, and the pump cover 11 includes a second sealing portion. The first sealing portion and the second sealing portion are sealed and fixed together, and the fixing method includes welding, bonding, etc. The welding method includes laser welding, friction welding, and ultrasonic welding. To further reduce the manufacturing cost of the electric pump 100, as shown in Figure 12, the second housing 1342 further includes a flange portion 1342c. Furthermore, along the radially outer side of the electric pump 100, the flange portion 1342c is provided radially outward of the radially extending segment 1342a, and the electric pump 100 includes a pump cover 11, the welding portion of the pump cover 11 is located above the flange portion 1342c, and the pump cover 11 and the flange portion 1342c are fixed and connected by welding. In this way, the number of fixing structural components for connecting the pump cover 11 and the stator unit 13, and the sealing structural components at the connection point between the pump cover 11 and the stator unit 13 can be reduced, further lowering the manufacturing cost of the electric pump 100.

[0027] The following describes the connection plate unit in detail. As shown in Figures 1 to 3 and Figures 12 to 19, the connecting plate unit 132 is positioned or fixedly connected to the end of the stator winding 131 along the axial direction of the electric pump 100, and is electrically connected to the winding 1313 of the stator winding 131. The first housing 1341 is formed by injection molding with at least the stator winding 131 and the connecting plate unit 132 as inserts, and at least a portion of the connecting plate unit 132 and a portion of the stator winding 131 are located within the first housing 1341. In this way, the electric pump 100 can be made smaller in the radial direction, and the assembly process of the electric pump 100 can be simplified by injection molding the connecting plate unit 132 and the stator winding 131 as inserts. To facilitate subsequent descriptions, the injection molding of the stator winding 131 and connecting plate unit 132 as inserts is defined as the first injection molding, and the injection molding of the first unit 136 and pump shaft 133 as inserts is defined as the second injection molding.

[0028] As shown in Figures 12 to 17, the connecting plate unit 132 includes a position limiting member 1321, a conductive member 1322, and a connector 1323. The position limiting member 1321 and the connector 1323 are injection-molded members, and the conductive member 1322 is a metal member. The conductive member 1322 includes a main body portion 1322a and a pin portion 1322b, which are fixedly connected or connected with positional restrictions. The main body portion 1322a and the pin portion 1322b may be an integrated structural component, or they may be separate structural components that are fixed and connected by welding, or electrical connection may be achieved after the main body portion 1322a and the pin portion 1322b are inserted together. The electric pump 100 includes a connecting pin (not shown), and the connecting pin and the conductive member 1322 may be an integrated structure or separate structures. One end of the connecting pin is electrically connected to the wiring end of the stator winding 131, and the other end is fixed and connected to the main body 1322a. The connector 1323 is connected to or fixed to the position limiting member 1321 in such a way that its position is restricted, and the connector 1323 has an insertion hole 1323a, at least a portion of the main body 1322a is fitted onto the position limiting member 1321, and at least a portion of the pin portion 1322b is located in the insertion hole 1323a. Thus, the connector 1323 may be injection molded in advance. Here, during the first injection molding, the connector 1323 is used as an insert to form the first housing 1341. In this way, the mold structure used during the first injection molding is simplified, which provides a certain basis for reducing the manufacturing cost of the electric pump 100.

[0029] As shown in Figures 1, 12 to 17, the main body 1322a and the pin portion 1322b are separate structures, the connector 1323 is connected to the position limiting member 1321 so as to be position-limited, and the pin portion 1322b includes an electrical connection portion 1322c, a base portion 1322d, and an external power supply connection portion 1322. The electrical connection portion 1322c is connected to the main body portion 1322a in a position-restricted manner, the base portion 1322d is injection-molded and fixed to the connector 1323, the external power connection portion 1322e is connected to an external power source, and at least a portion of the external power connection portion 1322e is located within the insertion hole 1323a. Thus, the unit formed by fixing at least a portion of the pin portion 1322b to the connector 1323 via injection molding is inserted into the conductive member 1322 fitted into the position limiting member 1321 to achieve electrical connection. In this way, the adaptability of the connecting plate unit 132 is improved, meaning that the unit formed by fixing at least a portion of the pin portion 1322b to the connector 1323 via injection molding can be applied to electric pumps 100 of different models, and furthermore, the manufacturing cost of the electric pump 100 can be reduced.

[0030] To reduce deformation of the connecting plate unit 132 during injection molding, as shown in Figures 1, 12 to 17, the insertion hole 1323a penetrates the connector 1323 in a direction parallel to the axial direction of the electric pump 100, and the insertion hole 1323a includes a first opening 1323b and a second opening 1323c. The first opening 1323b is closer to the position limiting member 1321 than the second opening 1323c, and the connecting plate unit 132 includes a pressure relief hole 1324, which penetrates the position limiting member 1321 in a direction parallel to the thickness direction of the position limiting member 1321, where the thickness direction of the position limiting member 1321 is parallel to the axial direction of the electric pump 100. Along the direction parallel to the axial direction of the electric pump 100, the wall portion corresponding to the first opening 1323b and the wall portion corresponding to the pressure relief hole 1324 are projected onto the upper surface of the position limiting member 1321, and the projection of the wall portion corresponding to the pressure relief hole 1324 is located within the projection of the wall portion corresponding to the first opening 1323b. The connector 1323 is fixedly connected to or positioned to the position limiting member 1321, and the first opening 1323b is located above the position limiting member 1321. During the first injection molding, the position limiting member 1321 corresponding to the first opening 1323b deforms due to the action of the injection molding pressure. Thus, the position limiting member 1321 corresponding to the first opening 1323b is provided with a pressure relief hole 1324, which releases at least a portion of the injection molding pressure during the first injection molding. In this way, deformation of the connecting plate unit 132 is reduced during the first injection molding, and the situation in which the electrical connection of the electric pump 100 becomes invalid is reduced.

[0031] In another implementation, as shown in Figures 1, 12 to 17, the insertion hole 1323 penetrates the connector 1323 along a direction parallel to the axial direction of the electric pump 100, and the insertion hole 1323 includes a first opening 1323b and a second opening 1323c. The first opening 1323b is positioned closer to the position limiting member 1321 relative to the second opening 1323c, and the connector 1323 further includes a plate portion 1323d, at least a portion of which is located at the first opening 1323b, and the plate portion 1323d has at least one perforation 1323e, and at least a portion of the outer wall of the plate portion 1323d is injection molded and fixed to the wall portion corresponding to the first opening 1323b. By positioning the plate portion 1323d, the strength of the connector 1323 is improved, deformation of the connecting plate unit 132 is reduced when it is injection molded as an insert, and the situation in which the electrical connection of the electric pump 100 becomes invalid is reduced.

[0032] The present invention further discloses a method for manufacturing an electric pump 100, which, as shown in Figures 1 to 17, includes a stator winding 131, a housing 134, and a pump shaft 133. The housing 134 includes a first housing 1341 and a second housing 1342. The first housing 1341 is formed by injection molding at least the stator windings 131 as an injection molding insert. An injection-molded member formed by injection molding the first housing 1341 and the stator windings 131 together is defined as a first unit 136. The second housing 1342 is formed by injection molding the first unit 136 and the pump shaft 133 as injection molding inserts. In this way, the second housing 1342 is fixed to the first unit 136 by injection molding, reducing the strength requirements of the second housing 1342 and the connection point between the second housing 1342 and the first unit 136, and further reducing the manufacturing cost of the second housing 1342 and the connection point between the second housing 1342 and the first unit 136, thereby reducing the manufacturing cost of the electric pump 100.

[0033] As shown in Figures 1 to 17, the electric pump 100 further includes a connecting plate unit 132, and the manufacturing method of the electric pump 100 includes the steps of: molding the connecting plate unit 132; assembling the connecting plate unit 132 to the end of the stator winding 131 and electrically connecting the connecting plate unit 132 and the stator winding 131; forming a first housing 1341 by injection molding the assembled member of the connecting plate unit 132 and the stator winding 131 as an injection molding insert; and defining an injection-molded member formed by injection molding the first housing 1341, the stator winding 131, and the connecting plate unit 132 as a first unit 136. In this way, the connecting plate unit 132 is manufactured and formed in advance, which contributes to miniaturizing the mold for the electric pump 100 and further reduces the manufacturing cost of the electric pump 100.

[0034] As shown in Figures 1 to 17, the connecting plate unit 132 includes a conductive member 1322 and a position limiting member 1321, and the electric pump 100 includes a connector 1323. The manufacturing method for this electric pump 100 includes the step of forming the position limiting member 1321 and the connector 1323 by injection molding the conductive member 1322 as an injection molding insert. In this way, when manufacturing the connecting plate unit 132, the position limiting member 1321 and the connector 1323 can be formed together by injection molding, simplifying the manufacturing process of the electric pump 100 and laying a certain foundation for reducing the manufacturing cost of the electric pump 100. Here, the conductive member 1322 includes a main body portion 1322a and a pin portion 1322b, which are fixed and connected or connected with positional restrictions. Furthermore, the main body portion 1322a and the pin portion 1322b may be an integrated structural component or separate structural components, and they may be fixed and connected by welding, or an electrical connection may be achieved after the main body portion 1322a and the pin portion 1322b are inserted together.

[0035] As another embodiment, as shown in Figures 1, 12 to 17, the connecting plate unit 132 includes a conductive member 1322, a position limiting member 1321, and a connector 1323. The manufacturing method of the electric pump 100 includes a step of molding the connector 1323. Specifically, the main body 1322a and the pin portion 1322b are separate structures. The connector 1323 is formed by injection molding the pin portion 1322b as an injection molding insert. The connector 1323 is connected to the position limiting member 1321 so as to be position-limited. The pin portion 1322b includes an electrical connection portion 1322c, a base portion 1322d, and an external power supply connection portion 1322. The electrical connection portion 1322c is connected to the main body portion 1322a in a position-restricted manner, the base portion 1322d is injection-molded and fixed to the connector 1323, the external power connection portion 1322e is connected to an external power source, and at least a portion of the external power connection portion 1322e is located within the insertion hole 1323a. The connector 1323 is assembled into a component formed by injection molding the conductive member 1322 and the position limiting member 1321. Thus, the connector 1323 is pre-manufactured and formed, laying a certain foundation for simplifying the structure of the injection molding die for the connecting plate unit 132.

[0036] As shown in Figures 1 to 17, the electric pump 100 further includes a rotary unit 12, the rotary unit 12 includes a rotor unit 122 and a blade unit 121, the electric pump 100 comprises a pump cavity 20, and a method for manufacturing the electric pump 100 includes the step of forming the rotary unit 12, the pump cavity 20 includes a communicating rotor cavity 141 and a blade cavity 15, a working fluid can flow through the pump cavity 20, the rotary unit 12 is located in the pump cavity 20, specifically, at least a portion of the rotor unit 122 is located in the rotor cavity 141 and the blade unit 121 is located in the blade cavity 15.

[0037] The electric pump 100 in Figures 1 to 17 includes a pump cover 11, and the manufacturing method of the electric pump 100 includes the step of forming the pump cover 11, the pump cover 11 being an injection molded member, and welding the pump cover 11 to the second housing 1342. In this way, the number of fixing structural components for connecting the pump cover 11 and the stator unit 13, and the sealing structural components at the connection point between the pump cover 11 and the stator unit 13 can be reduced, further lowering the manufacturing cost of the electric pump 100.

[0038] As shown in Figures 1 to 19, the parting surface A forming the first housing 1341 and the parting surface B forming the second housing 1342 are on the same plane. Thus, the first unit 136, formed with at least the stator winding 131 as an insert, proceeds to the next injection molding step without being demolded from a part of the injection molding die, and in the next injection molding step, at least the first unit 136 and the pump shaft 133 are injection molded as inserts. Since the first parting surface A and the second parting surface B are on the same plane, at least the first unit 136 formed with the stator winding 131 as an insert does not demold from a part of the injection molding die, and the positioning error due to repeated clamping with the injection molding die when the first unit 136 is used as an insert is reduced, thereby reducing the coaxial accuracy between the pump shaft 133 and the stator winding 131. As shown in Figures 13 and 14, the injection molding die is defined to include a first mold C. During the first injection molding, the die used is the first mold C. After the first injection molding is completed, a portion of the first mold is demolded, and the first unit 136 is located in the first mold C. During the second injection molding, a portion of the first mold C and the second mold D work together to complete the second injection molding. Thus, when at least the pump shaft 133 is used as an insert during the second injection molding, the same positioning criteria can be used to position the stator core 1311 in both the second and first injection molding processes. This reduces the positioning error between the first unit 136 and the second mold D, thereby improving the coaxiality between the pump shaft 133 and the stator core 1311.

[0039] Herein, the above embodiments are not limiting to the present invention, but are used merely to illustrate the present invention. Although this specification has already described the present invention in detail with reference to the above embodiments, those skilled in the art will understand that they may still amend or substitute equivalents to the present invention, and any improvements that do not depart from the spirit and scope of the invention should fall within the scope of the claims of this application. [Explanation of symbols]

[0040] 100... Electric pump 11... Pump cover 12 ··· Rotating Unit 121 ···Blade Unit 122 ···Rotor Unit 13 ···Stator Unit 131 ···Stator winding 1311 ··· Stator Core 1311a...first end 1311b...Second end 1311c ···Positioning section 1312 ···Insulating frame 1313 ···winding 132 ···Connecting plate unit 1321 ···Position limiting member 1322 ···Conductive component 1322a...Main body 1322b ···Pin part 1322c ···Electrical connection 1322d...Base 1322e ···External power connection section 1323 ··· Connector 1323a ···Insertion hole 1323b...1st hole 1323c...Second hole 1323d ···Plate part 1323e ···Watermark 1324 ···Pressure relief hole 133... Pump shaft 1331...Fixed part 1332 ···Rotating part 134 ···Housing 1341 ···First Housing 1341a...1st body part 1341b ···First edge section 1341c...1st end surface 1341d...Second end surface 1342 ···Second Housing 1342a ···Radially extending segment 1342b...Cylinder part 1342c ···Flange section 136 ···Unit 1 1362 ···First Cavity 1362a...bottom 1362b ···Side 141 ···Rotatum Cavity 1411 ···Bottom of the rotor cavity 1412 ···Rotor cavity side 15... Blade cavity 20 ···Pump Cavity 101 / 101'...1st reference plane A ···First parting surface B...Second parting surface C ···First mold D...Second mold.

Claims

1. An electric pump (100), Including stator windings (131), housing (134), and pump shaft (133), The housing (134) includes a first housing (1341) and a second housing (1342), At least a portion of the first housing (1341) is formed to be injection molded with the stator winding (131) as an insert, The first unit (136) is defined to include the first housing (1341) and the stator winding (131), At least a portion of the second housing (1342) is formed to be injection molded with the first unit (136) and the pump shaft (133) as inserts, The first housing (1341) includes a first parting surface (A), The second housing (1342) includes a second parting surface (B), The electric pump (100) is characterized in that the first parting surface (A) and the second parting surface (B) are on the same surface.

2. The electric pump (100) further includes a connecting plate unit (132), The connecting plate unit (132) is positioned along the axial direction of the electric pump (100) so as to be restricted in position by the stator winding (131), or is fixed and connected to it. The connecting plate unit (132) is electrically connected to the winding (1313) of the stator winding (131), The electric pump (100) according to claim 1, characterized in that at least a portion of the first housing (1341) is formed to be injection molded with the stator winding (131) and the connecting plate unit (132) as inserts.

3. The first housing (1341) includes a first main body portion (1341a) and a first edge portion (1341b), The first main body portion (1341a) is formed by injection molding with the stator winding (131) as an insert. The stator winding (131) includes the stator core (1311), The stator core (1311) includes a first end (1311a) and a second end (1311b), The first edge portion (1341b) is provided on the radially outer side of the first main body portion (1341a), The first edge portion (1341b) approaches the first end portion (1311a), The electric pump according to claim 1 or 2, characterized in that the first edge portion (1341b) is located between the first end portion (1311a) and the second end portion (1311b) in a direction parallel to the axial direction of the electric pump (100).

4. The first edge portion (1341b) includes a first end face (1341c) and a second end face (1341d), Along the direction parallel to the electric pump, the first end face (1341c) approaches the first end (1311a) relative to the second end face (1341d), and the surface on which the first parting surface (A) or the second parting surface (B) is located is defined as the first reference surface (101). The plane on which the first reference plane (101) and the second end face (1341d) are located is the same plane, or, along the axial direction of the electric pump (100), the second end face (1341d) approaches the second end (1311b) relative to the first end face (1341c), and the plane on which the first parting plane (A) or the second parting plane (B) is located is defined as the first reference plane (101'), The electric pump according to claim 3, characterized in that the first reference plane (101') is located between the plane on which the second end face (1341d) is located and the plane on which the first end face (1341c) is located, or the first reference plane (101') and the plane on which the first end face (1341c) is located are on the same plane.

5. The first unit (136) comprises a first cavity (1362), The wall portion corresponding to the first cavity (1362) includes a bottom portion (1362a) and a side portion (1362b), The second housing (1342) includes a rotor cavity bottom (1411) and a rotor cavity side (1412), The rotor cavity bottom (1411) and the rotor cavity side (1412) are sealed and connected by injection molding. The rotor cavity bottom (1411) is located above the bottom (1362a) of the first cavity (1362). The rotor cavity bottom (1411) is positioned to contact the bottom (1362a) of the first cavity (1362). In the radial direction of the electric pump (100), the bottom portion (1411) of the rotor cavity covers the bottom portion (1362a) of the first cavity (1362). The rotor cavity side portion (1412) is positioned radially inward of the side portion (1362b) of the first cavity (1362) and is arranged to contact the side portion (1362b) of the first cavity (1362). The electric pump according to any one of claims 1 to 4, characterized in that the rotor cavity side portion (1412) covers the side portion (1362b) of the first cavity (1362) along the circumferential direction of the side portion (1362b) of the first cavity (1362).

6. The electric pump according to claim 5, characterized in that the inner wall surface of the side portion (1362b) includes the inner wall surface of the stator core (1311) and the inner wall surface of the first housing (1341).

7. The second housing (1342) further includes a radially extending segment (1342a), The radially extending segment (1342a) is sealed and connected to one end of the rotor cavity side portion (1412), The radially extending segment (1342a) along the axial direction of the electric pump is separated from the bottom (1362a) relative to the bottom (1411) of the rotor cavity. The radially extending segment (1342a) is injection molded and fixed to the end of the first unit (136). The electric pump (100) includes a blade cavity (15) and a rotor cavity (141) that are in communication with each other. The wall portion corresponding to the rotor cavity (141) includes the rotor cavity bottom portion (1411) and the rotor cavity side portion (1412), The electric pump (100) according to claim 5 or 6, characterized in that the wall portion corresponding to the blade cavity (15) includes at least a portion of the radially extending segment (1342a).

8. The pump shaft (133) includes a fixed part (1331) and a rotating part (1332), The fixing portion (1331) is fitted into the bottom portion (1411) of the rotor cavity. At least a portion of the rotating part (1332) is located in the rotor cavity (141), The electric pump (100) according to any one of claims 5 to 7, characterized in that a part of the rotor cavity bottom (1411) encloses the end of the fixing part (1331).

9. The electric pump according to any one of claims 1 to 8, characterized in that the material of the first housing (1341) is different from the material of the second housing (1342).

10. The hydrolysis resistance of the material of the first housing (1341) is lower than that of the polyphenylene sulfide material. The electric pump according to claim 9, characterized in that the hydrolysis resistance of the material of the second housing (1342) is greater than or equal to that of the polyphenylene sulfide material.

11. A method for manufacturing an electric pump (100), The steps include forming a first housing (1341) by injection molding at least the stator winding (131) as an insert, and defining a first unit (136) to include the first housing (1341) and the stator winding (131), A method for manufacturing an electric pump (100), comprising the step of forming a second housing (1342) by injection molding the first unit (136) and the pump shaft (133) as inserts.

12. The electric pump (100) further includes a connecting plate unit (132), The method for manufacturing the electric pump (100) according to claim 11, comprising the steps of: molding the connecting plate unit (132); assembling the connecting plate unit (132) and the stator winding (131) to electrically connect them; and forming the first housing (1341) by injection molding the connecting plate unit (132) and the stator winding (131) as inserts.

13. A method for manufacturing an electric pump according to claim 11 or 12, characterized by including the step of positioning the parting surface forming the first housing (1341) and the parting surface forming the second housing (1342) on the same plane.

14. The method for manufacturing an electric pump (100) according to claim 13, characterized in that the first unit (136), formed with at least the stator winding (131) as an insert, proceeds to the next injection molding step without being demolded from a part of the injection molding die, and the next injection molding step includes a step of injection molding with at least the first unit (136) and the pump shaft (133) as inserts.

15. A method for manufacturing an electric pump (100) according to any one of claims 11 to 14, characterized in that the injection molding material used to form the first housing (1341) is different from the injection molding material used to form the second housing (1342).

Images