Electric device and motor

Abstract

The present application discloses an electric device and a motor. The electric device comprises: a motor, comprising a stator and a rotor, the rotor rotating about a first axis; and an output portion configured to be driven by power provided by the motor. The stator comprises a stator core and a winding. The stator core comprises: a yoke portion, and tooth portions extending from the yoke portion to the rotor, wherein the plurality of tooth portions are circumferentially arranged along the axis of the rotor, and two adjacent tooth portions define a stator slot for accommodating the winding. The winding comprises a coil and a cage for supporting the coil, the winding is at least partially arranged in the stator slots, wherein the cage is provided with a filling portion, the filling portion is configured to fill a gap inside the winding, and the filling portion at least comprises a thermally-conductive and non-magnetically conductive material.

Description

Electric equipment and motors

[0001] This application claims priority to Chinese patent applications filed on November 8, 2024, application number 202411597435.9 and September 19, 2025, application number 202511352980.6, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This application relates to an electric device, such as an electric device and motor driven by an electric motor. Background Technology

[0003] In related technologies, electric devices include motors connected to a power source to provide power to the electric devices. The motor can be a direct current (DC) motor. The motor includes a stator and a rotating rotor. The stator includes a stator core and windings. Stator slots are formed circumferentially on the stator core, and the windings are wound around the stator core through these slots. In related technologies, a semi-closed slot structure is typically used, resulting in a small slot opening size, making it difficult to achieve a high slot fill factor when winding through the slot openings. Loose wires also have poor thermal conductivity, affecting heat dissipation from the windings.

[0004] This section provides background information related to this application, which is not necessarily prior art. Summary of the Invention

[0005] One objective of this application is to provide a motor and electric device with good thermal conductivity.

[0006] To achieve the above objectives, this application adopts the following technical solution:

[0007] An electric device includes: a motor including a stator and a rotor, the rotor rotating about a first axis; an output section configured to be driven by power provided by the motor; wherein the stator includes: a stator core and a winding; the stator core includes: a yoke and teeth extending from the yoke toward the rotor, a plurality of teeth being arranged circumferentially along the axis of the rotor, adjacent teeth defining stator slots for receiving the winding; the winding includes a coil and a cage supporting the coil, the winding being at least partially disposed in the stator slot, wherein the cage is provided with a filler portion configured to fill gaps present inside the winding, the filler portion comprising at least a thermally conductive but non-magnetically conductive material.

[0008] In some embodiments, the gap includes at least the gap between coils and the gap between a coil and a cage.

[0009] In some embodiments, the stator slots are provided with openings; the windings are integrally embedded into the stator slots through the openings.

[0010] In some embodiments, the cage includes a support portion disposed on the outer periphery of the teeth, the coil is supported by the support portion, and a filler portion is formed in the support portion.

[0011] In some embodiments, the filler portion is formed on the support portion by injection molding.

[0012] In some embodiments, after the coil is directly wound and shaped on the support, the material constituting the filling portion is filled or applied to the outer periphery of the coil by injection molding.

[0013] In some embodiments, the filling portion, the support portion, and the coil are injection molded as a single unit.

[0014] In some embodiments, after the coil wire is independently wound and formed, the outer periphery of the formed coil is injection molded to form a support portion.

[0015] In some embodiments, the filler portion is integrally injection molded onto the outer periphery of the coil to fill the gaps between the coils.

[0016] In some embodiments, the cage further includes a first end face disposed at one axial end of the support portion, the first end face extending radially along the support portion, and a second end face disposed at the other axial end of the support portion, the second end face extending radially along the support portion, and the first end face being connected to the inner side of the yoke portion.

[0017] In some embodiments, the slot fill factor of the motor is greater than or equal to 40% and less than or equal to 70%.

[0018] In some embodiments, the stator includes a plurality of windings, the cage of the windings is provided with a connecting portion, and the plurality of windings are interconnected through the connecting portion.

[0019] In some embodiments, the connection restricts radial and axial movement of the winding relative to the stator core.

[0020] In some embodiments, the stator further includes a limiting portion connected to the stator core, which restricts the radial and axial movement of the winding relative to the stator core.

[0021] In some embodiments, the openings on the stator core are configured as openings of equal width.

[0022] An electric motor includes: a rotor that rotates about a first axis; a stator including a stator core and windings; wherein the stator core includes: a yoke and teeth extending from the inside of the yoke, a plurality of teeth being arranged circumferentially along the axis of the rotor, and adjacent teeth defining stator slots for receiving windings; the windings include coils and a cage supporting the coils, the windings being embedded in the stator slots, wherein the cage is provided with a filler portion configured to fill gaps present inside the windings, the filler portion comprising at least a thermally conductive but non-magnetically conductive material.

[0023] In some embodiments, the gap includes at least the gap between coils and the gap between a coil and a cage.

[0024] In some embodiments, the stator slots are provided with openings; the windings are integrally embedded into the stator slots through the openings.

[0025] In some embodiments, the slot fill factor of the motor is greater than or equal to 40% and less than or equal to 70%.

[0026] In some embodiments, the cage includes a support portion disposed on the outer periphery of the teeth, the coil is supported by the support portion, and a filler portion is formed in the support portion. In some embodiments, the stator further includes a limiting portion connected to the stator core, the limiting portion restricting radial and axial movement of the winding relative to the stator core. Attached Figure Description

[0027] Figure 1 is a schematic diagram of the structure of an electric device according to an embodiment of this application;

[0028] Figure 2 is a schematic diagram of the internal structure of an electric device according to an embodiment of this application;

[0029] Figure 3 is a schematic diagram of a motor according to an embodiment of this application;

[0030] Figure 4 is a schematic diagram of the rotor of an electric motor according to an embodiment of this application;

[0031] Figure 5 is a schematic diagram of the stator of an electric motor according to an embodiment of this application;

[0032] Figure 6 is a schematic diagram from another perspective of Figure 5;

[0033] Figure 7 is an exploded view of Figure 5;

[0034] Figure 8 is a schematic diagram of the structure of the stator core in Figure 5;

[0035] Figure 9 is a schematic diagram of the winding structure in Figure 5;

[0036] Figure 10 is a schematic diagram of the stator core structure according to the second embodiment of this application;

[0037] Figure 11 is a schematic diagram of the winding structure according to the second embodiment of this application.

[0038] Figure 12 is a schematic diagram of the stator core structure of the third embodiment of this application. Detailed Implementation

[0039] Before explaining any implementation of this application in detail, it should be understood that this application is not limited to its application to the structural details and component arrangements set forth in the following description or shown in the above drawings.

[0040] In this application, the terms "comprising," "including," "having," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

[0041] In this application, the term "and / or" describes the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent three cases: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this application generally indicates that the preceding and following related objects have an "and / or" relationship.

[0042] In this application, the terms "connection," "combination," "coupling," and "installation" can refer to direct connection, combination, coupling, or installation, or indirect connection, combination, coupling, or installation. For example, a direct connection refers to two parts or components being connected together without the need for an intermediary, while an indirect connection refers to two parts or components each being connected to at least one intermediary, with the connection achieved through the intermediary. Furthermore, "connection" and "coupling" are not limited to physical or mechanical connections or couplings, but can also include electrical connections or couplings.

[0043] In this application, those skilled in the art will understand that relative terms (e.g., “about,” “approximately,” “basically,” etc.) used in conjunction with quantities or conditions are to include the values ​​and have the meaning indicated by the context. For example, such relative terms include at least the degree of error associated with the measurement of a particular value, tolerances associated with the particular value due to manufacturing, assembly, use, etc. Such terms should also be considered as disclosing a range defined by the absolute values ​​of the two endpoints. Relative terms may refer to a certain percentage (e.g., 1%, %, 1% or more) of the indicated value. Numerical values ​​that do not use relative terms should also be disclosed as specific values ​​with tolerances. Furthermore, “basically” when expressing relative angular relationships (e.g., substantially parallel, substantially perpendicular) may refer to a certain degree (e.g., 1 degree, 1 degree, 1 degree or more) added to or subtracted from the indicated angle.

[0044] In this application, those skilled in the art will understand that the function performed by a component can be performed by one component, multiple components, one part, or multiple parts. Similarly, the function performed by a part can also be performed by one part, one component, or a combination of multiple parts.

[0045] In this application, the directional terms "upper," "lower," "left," "right," "front," and "rear" are used to describe the orientation and positional relationships shown in the accompanying drawings and should not be construed as limiting the embodiments of this application. Furthermore, in the context, it should be understood that when an element is mentioned as being connected "upper" or "lower" to another element, it can be directly connected to the other element "upper" or "lower," or indirectly connected through an intermediate element. It should also be understood that directional terms such as upper side, lower side, left side, right side, front side, and rear side not only represent positive orientation but can also be understood as lateral orientation. For example, "below" can include directly below, lower left, lower right, lower front, and lower rear.

[0046] In this application, the terms "controller," "processor," "central processing unit," "CPU," and "MCU" are used interchangeably. When using the unit "controller," "processor," "central processing unit," "CPU," or "MCU" to perform a specific function, unless otherwise stated, these functions may be performed by a single or multiple of the aforementioned units.

[0047] In this application, the terms "device," "module," or "unit" are used to describe devices that can be implemented in hardware or software to perform a specific function.

[0048] In this application, the terms “calculation,” “judgment,” “control,” “determine,” “identify,” etc., refer to the operation and process of a computer system or similar electronic computing device (e.g., controller, processor, etc.).

[0049] As shown in Figures 1 and 2, this application discloses an electric device 100, such as a lawnmower. The electric device 100 includes a motor 30 and an output unit 20. The motor 30 generates power to drive the output unit 20, and the output unit 20 is driven by the power transmitted by the motor 30. The motor 30 includes a stator 31 and a rotor 32, the rotor 32 rotating about a first axis 301. The stator 31 includes a stator core 311 and windings 312. The rotor 32 is formed with or connected to a rotor shaft 321, the rotor shaft 321 rotating about the first axis 301 and outputting power. In the lawnmower product, the output unit 20 includes blades for cutting vegetation, and the rotor shaft 321 drives the output unit 20, causing the output unit 20 to rotate about the output axis 201. In this embodiment, the first axis 301 and the output axis 201 are coaxially arranged. In some embodiments, the first axis 301 and the output axis 201 are parallel but not coaxially arranged. In some embodiments, the first axis 301 and the output axis 201 intersect.

[0050] In some embodiments, a transmission component, an impact component, or a reversing component may be provided between the motor 30 and the output unit 20, depending on the different functions of the different electric devices 100. This does not affect the substantive content of this application.

[0051] In some embodiments, the power device 100 may also be other garden tools, such as lawn mowers, hair dryers, and walk-behind power tools such as snowplows, chainsaws, and washers. In some embodiments, the power device 100 may also be other handheld tools, such as screwdrivers, drills, wrenches, impact drills, hammer drills, nail guns, sanders, reciprocating saws, jigsaws, circular saws, angle grinders, and angle tools. In some embodiments, the power device 100 may also be benchtop tools, such as table saws and miter saws. In some embodiments, the power device 100 may also be, for example, fans and electric camping vehicles.

[0052] In some embodiments, the electric device 100 also includes outdoor mobility devices, such as ride-on lawnmowers and snowplows. It can also be other vehicles that travel only outdoors, such as multi-purpose vehicles, ATVs, utility vehicles (UTVs), golf carts, and all-terrain vehicles (ATVs). It can also be agricultural machinery vehicles, such as harvesters and sprayers. It is understood that the output unit 20 can be a walking wheel, and the motor 30 is the walking motor. In some embodiments, the output unit 20 can be a functional component such as a blade or snowplow, and the motor 30 is the motor that performs the function.

[0053] It is understood that any electric device 100 driven by the motor 30 can adopt the technical solution disclosed in this embodiment, and all power devices adopting the technical solution disclosed in this embodiment fall within the scope of protection of this application. For example, the electric device 100 can also be a power head, which includes the motor 30. The power head is used to adapt some output components to realize the function of the tool.

[0054] As shown in Figures 1 and 2, a lawnmower is used as an example. The lawnmower includes a power supply 40. In this embodiment, the power supply 40 is a DC power supply. The DC power supply provides electrical energy to the lawnmower. The DC power supply is a battery pack, which, in conjunction with corresponding power circuitry, supplies power to the lawnmower. Those skilled in the art should understand that the power supply 40 is not limited to scenarios using DC power; it can also supply power to corresponding components within the machine through mains power or AC power, in conjunction with corresponding rectification, filtering, and voltage regulation circuitry. In the following description, the battery pack 40 will be used instead of the power supply, but this should not be construed as a limitation of the present invention.

[0055] The battery pack 40 provides a nominal voltage of 10V or greater and 120V or less. In some embodiments, the nominal voltage of the battery pack 40 is 10.8V, 18V, 24V, 36V, 48V, 56V, or 80V, 120V. In some embodiments, the battery pack 40 may be a lithium battery pack, a solid-state battery pack, or a pouch battery pack. In some embodiments, the battery pack 40 includes lithium iron phosphate cells. In some embodiments, the battery pack 40 disclosed in this application includes ternary lithium cells. In some embodiments, the battery pack 40 may also be a supercapacitor, also known as an electrochemical capacitor. The nominal voltage typically refers to the voltage specified by the manufacturer or distributor on the product's label, packaging, user manual, instruction manual, advertisement, marketing, or other supporting documents, so that users know which products and battery packs can operate interchangeably. Alternatively, the nominal voltage of the battery pack 40 can also be obtained by detection or calculation.

[0056] As shown in Figure 3, in this embodiment, the motor 30 is an inner rotor brushless motor 30. In other alternative embodiments, the motor 30 is an outer rotor brushless motor 30. For the inner rotor motor 30, the stator 31 is sleeved outside the rotor 32. For the outer rotor motor 30, the rotor 32 is sleeved outside the stator 31. In this embodiment, the brushless motor is configured as a three-phase brushless motor. It is understood that the motor 30 is not limited to a three-phase brushless motor, and can also be other types of DC motors; the above does not affect the substantive content of this application.

[0057] As shown in Figure 4, in this embodiment, the motor 30 is an internal rotor brushless DC motor. The motor 30 includes a stator 31 and a rotor 32. The rotor 32 includes a rotor core 322, and the rotor core 322 is provided with permanent magnets 323. The permanent magnets 323 are arranged along the axis of the rotor core 322 and are used to generate a magnetic field. The rotor core 322 has slots for placing the permanent magnets 323. The rotor 32 is formed with or connected to a rotor shaft 321, which rotates about a first axis 301.

[0058] As shown in Figures 5 to 12, the stator includes a stator core and windings. The stator core includes a yoke and teeth extending from the yoke towards the rotor. Multiple teeth are arranged circumferentially along the rotor axis, and adjacent teeth define stator slots that accommodate the windings. The windings include coils and a cage supporting the coils, with the windings at least partially disposed in the stator slots. Coils belonging to the same phase are connected in series and parallel, and then connected in a delta or Y-shape configuration between phases to form the motor's input and output lines 30. The coils are made of conductive metal, such as copper wire.

[0059] As shown in Figures 5 to 9, a motor of an electric device according to an embodiment of this application is provided. The motor is configured as a radial magnetic field motor. In this embodiment, the stator 31 includes a stator core 311 and a winding 312. The stator core 311 includes a yoke 3111 and teeth 3112 extending radially from the yoke 3111 towards the rotor 32. A plurality of teeth 3112 are arranged along the axis of the rotor 32, and adjacent teeth 3112 define stator slots 3113 for accommodating the winding 312. Exemplarily, the plurality of teeth 3112 are arranged circumferentially spaced along the rotor 32. The winding 312 includes a coil 3121 and a retainer 3122 supporting the coil 3121. The winding 312 is at least partially disposed in the stator slot 3113. Exemplarily, the winding 312 is inserted into the stator slot. The coils 3121 belonging to the same phase are connected in series and parallel, and then connected in a delta or Y-shape between phases to form the input and output lines of the motor 30. The coils 3121 are coils of conductive metal, such as copper wire.

[0060] In this embodiment, the cage 3122 is provided with a filling portion 3123, which is configured to fill the gaps present inside the winding 312, and the filling portion 3123 is made of at least a thermally conductive but non-magnetic material. Exemplarily, the gaps include at least the gaps between coils and between the coil and the cage. By using the aforementioned thermally conductive but non-magnetic material, the air between the coils 3121 can be effectively replaced, reducing or eliminating air gaps, thereby forming a thermally conductive and tightly structured whole among the multi-turn coils 3121, significantly improving the axial and radial thermal conductivity of the winding 312. The thermally conductive filling material establishes an efficient heat conduction path, enabling rapid heat dissipation from hot spots inside the coil, effectively reducing the local and overall operating temperature of the winding 312, and improving the power density and operational reliability of the motor. Secondly, the non-magnetic properties of the filling portion 3123 avoid the generation of additional eddy current losses, ensuring the electrical performance of the winding 312. Furthermore, the composite material can enhance the mechanical support and insulation protection between the coils, improving the overall integrity, vibration resistance, and long-term stability of the winding.

[0061] For example, thermally conductive but non-magnetic materials include composite materials composed of organic resins and inorganic fillers. The most commonly used organic resin is epoxy resin, but modified epoxy resins such as polyvinyl butyral, acrylate, and polyurethane are also frequently used. Other types of resins can also be selected, such as phenolic resins, polyimide resins, polyethylene terephthalate, and polyphenylene ether. Inorganic fillers include Al₂O₃, MgO, ZnO, BeO, Si₃N₄, and AlN.

[0062] The stator slot 3113 is provided with a radial opening 3114 facing the rotor 32, and the winding 312 is inserted entirely into the stator slot 3113 through the opening 3114. In this embodiment, the stator core 311 is provided with a rotor hole 313 for accommodating the rotor 32, and the rotor 32 can rotate within the rotor hole 313. Teeth 3112 extend radially from the yoke 3111 toward the rotor hole 313. A plurality of teeth 3112 are arranged along the axis of the rotor hole 313. A stator slot 3113 is formed between adjacent teeth 3112. The stator slot 3113 has a radial opening 3114 facing the rotor hole 313 on the side near the rotor 32.

[0063] The winding 312 is composed of a coil 3121 and a cage 3122 for supporting the coil 3121. The coil 3121 is wound around the cage 3122 to form a continuous winding, thus forming an integral winding structure. The winding 312 is inserted into the stator slot 3113 through a radial opening 3114. The coil 3121 is wound continuously on the cage 3122 to form an integral winding 312, and the integral winding 312 formed by the coil 3121 and the cage 3122 is inserted into the stator slot 3113 through this radial opening 3114.

[0064] In related technologies, to improve the slot fill factor of the motor 30, a pre-formed flat wire coil 3121 is axially inserted into the stator slot 3113 to form a winding 312. This method is not suitable for small motors 30 with multiple slots and concentrated windings 312. In related technologies, for small motors 30 with multiple slots and concentrated windings 312, a common method is to embed the pre-formed winding 312 on the teeth or pre-wound the winding 312 on the teeth, and then assemble the teeth with the winding 312 onto the yoke 3111 of the stator 31. However, this makes it difficult to assemble the stator core 311, introduces an air gap, and reduces the stiffness of the stator core 311. In this embodiment, an open slot is provided in the stator core 311, and the winding 312, which consists of the coil 3121 and the cage 3122, is radially embedded in the stator slot 3113 through the opening 3114. This significantly improves assembly convenience and avoids the air gap and stiffness degradation problems caused by separate assembly, effectively maintaining the structural integrity of the stator core 311. At the same time, by pre-winding the coil 3121 onto the cage 3122 to form an integral winding, the coil can be tightly arranged in the slot, thereby significantly improving the slot fill factor, reducing copper loss, and further improving the efficiency and power density of the motor.

[0065] As shown in Figure 8, the stator core 311 is made of a metal with iron as its main component. The stator core 311 includes a yoke 3111 with a circular outer contour, the yoke 3111 having a central axis 301. Multiple teeth 3112 extend radially from the inner side of the yoke 3111, wherein the teeth 3112 and the yoke 3111 are integrally formed, that is, the teeth 3112 and the yoke 3111 are a single component. The multiple teeth 3112 are arranged along the axis. For example, 12 teeth 3112 are provided, each tooth 3112 supporting at least one winding 312.

[0066] In this embodiment, 12 windings 312 are provided, each winding 312 corresponding to a tooth 3112. As shown in FIG9, the retainer 3122 of the winding 312 further includes a support portion 3124, which at least partially comprises a thermally conductive but non-magnetically conductive material. Optionally, the support portion 3124 at least partially comprises a thermally conductive and insulating material. In this embodiment, the support portion 3124 is generally cylindrical, with a quadrilateral cross-section, and is disposed on the outer periphery of the tooth 3112, into which the tooth 3112 is inserted. Exemplarily, the support portion 3124 is provided with a through hole 3125 matching the structural shape of the tooth 3112 for insertion of the tooth 3112, and the through hole 3125 extends radially along the stator core 311.

[0067] The coil 3121 is supported by the support portion 3124. Exemplarily, the coil 3121 is wrapped around the outer periphery of a cylindrical tube. In this embodiment, the cross-sectional shape of the coil 3121 can be circular, a flat wire coil, or an irregularly shaped coil. In some embodiments, the coil 3121 is directly wound onto the outer periphery of the support portion 3124. Exemplarily, the support portion 3124 is held on a pre-defined clamp, and the wire constituting the coil 3121 is continuously fed out by a wire feeding device and uniformly wound around the periphery of the support portion 3124. After winding is completed, the filler portion 3123 is formed on the support portion 3124 by an injection molding process. Optionally, after the coil 3121 is wound, the material constituting the filler portion 3123 is applied between the coils 3121 by injection molding or coating to fill various gaps between coils 3121 and between coils 3121 and the support portion 3124. After the filler portion 3123 is filled with adhesive, it cures, and the winding 312, consisting of the cage 3122 and the coil 3121, is prefabricated as a whole. That is, the winding 312 is prefabricated as a complete component independently of the stator core 311. The prefabricated winding 312 facilitates the shaping of the coil 3121. Because the coil shaping process is more controllable, the shape of the coil 3121 can be optimized, thereby improving the slot fill factor of the motor 30. In one example, the slot fill factor of the motor 30 is greater than or equal to 40% and less than or equal to 70%. Exemplarily, the filler portion 3123 includes thermally conductive but non-magnetic materials, including epoxy resin, polyurethane, and silicone gel. These materials are initially flowable and, after filling the gaps inside the winding, can cure into a gel-like solid under specific conditions, thereby achieving good insulation and thermal conductivity.

[0068] In some embodiments, the coil 3121 is pre-formed and then encapsulated on the outside of the support portion 3124 by an integral injection molding process. Using integral injection molding, the coil 3121, support portion 3124, and filler portion 3123 are injection molded into a single unit. Exemplarily, a corresponding mold is secured on a specified fixture, and the wire is wound into a coil 3121 of a specified shape with the aid of the mold. After demolding from the mold, it is placed in an injection mold, where the support portion 3124 and filler portion 3123 are injection molded around the outer periphery of the coil 3121, also filling the gaps between the coils during the injection molding process. By using the injection molding process to integrally mold the coil 3121, support portion 3124, and filler portion 3123, the winding 3122, consisting of the cage 3122 and the coil 3121, is pre-fabricated as a whole. That is, the winding 312 is pre-manufactured as a complete component independently of the stator core 311. Using an integral injection molding process similar to encapsulation technology, the filler part 3123 contains at least epoxy resin material, which has good sealing performance, thermal conductivity and mechanical support strength.

[0069] In this embodiment, the openings 3114 on the stator core 311 are of equal width, and exemplarily, the teeth 3112 on the stator core 311 have an equal width tooth structure. In this embodiment, 12 teeth 3112 are provided, and the teeth 3112 are arranged at 30° intervals in the circumferential direction. The stator core 311 comprises multiple steel plates stacked axially, which are plates made of a metal with iron as the main component. The stator core 311 is formed by stacking multiple steel plates. The pre-formed winding 312 enters the rotor hole 313 along the axial direction of the stator core 311, and the teeth 3112 enter the support portion 3124 along the radial direction of the winding 312 along the stator core 311.

[0070] The retainer 3122 also includes a first end face 3122A disposed at one axial end of the support portion 3124, the first end face 3122A extending radially along the support portion 3124, and a second end face 3122B disposed at the other axial end of the support portion 3124, the second end face 3122B extending radially along the support portion 3124, and the first end face 3122A is connected to the inner side of the yoke portion 3111.

[0071] In some embodiments, after the pre-assembled integral winding 312 is installed on the stator core 311, to prevent the winding 312 from detaching from the stator core 311, optionally, a connecting portion (not shown) is provided on the cage 3122. Connectors between multiple windings 312 are interconnected, restricting the radial and axial movement of the windings 312 relative to the stator core 311. Exemplarily, the cage 3122 is provided with a first connecting member and a second connecting member on both sides of the stator core 311 circumferentially. The first and second connecting members are interlocked with a male-female mating structure, so that the first and second connecting members of adjacent cages 3122 interlock after connection, preventing relative movement between adjacent cages 3122 along the radial and axial directions of the stator core 311. After all cages 3122 are installed on the stator core 311, the cages 3122 are connected in pairs sequentially, and the multiple windings 312 are connected to form a stable integral structure. This allows the winding 312 to be stably installed in the stator core 311.

[0072] In some embodiments, to prevent the winding 312 from detaching from the stator core 311, the stator 31 includes a limiting portion 3126, which is connected to the stator core 311 in a limiting manner, restricting the radial and axial movement of the winding 312 relative to the stator core 311. Exemplarily, the limiting portion 3126 is located on the outer periphery of the winding 312, limiting the winding 312 axially and radially.

[0073] In some embodiments, the limiting part 3126 includes a body part and a limiting hole provided on the body part. The shape of the limiting hole is substantially consistent with the outer contour of the pre-made winding 312. The limiting part 3126 is installed at one end of the stator core 311 along the axial direction of the stator core 311, and the winding 312 is inserted into the limiting hole.

[0074] For example, after the limiting part 3126 is connected to the stator core 311, the relative movement of the winding 312 along the radial and axial directions of the stator core 311 is restricted. For example, the limiting part 3126 is connected to the stator core 311 via mechanical structures such as snaps, hooks, or pin holes. For example, the limiting part 3126 is connected to the stator core 311 via screws, latches, or other fastener structures. For example, the limiting part 3126 is fixedly connected to the stator core 311 by adhesive bonding, welding, or riveting.

[0075] This application also discloses a motor 30, which includes a rotor 32 and a stator 31. The rotor 32 rotates around a first axis 301. A rotor shaft 321 is formed or connected to the rotor 32, and the rotor shaft 321 rotates around the first axis 301 and outputs power. The stator 31 includes a stator core 311 and windings 312. In this embodiment, the motor 30 is an inner rotor brushless motor 30. In other alternative embodiments, the motor 30 is an outer rotor brushless motor 30. For the inner rotor motor 30, the stator 31 is sleeved outside the rotor 32. For the outer rotor motor 30, the rotor 32 is sleeved outside the stator 31. In this embodiment, the brushless motor 30 is configured as a three-phase brushless motor 30. It is understood that the motor 30 is not limited to a three-phase brushless motor 30, and can also be other types of DC motors; this does not affect the substantive content of this application.

[0076] In this embodiment, the stator 31 includes a stator core 311 and a winding 312. The stator core 311 includes a yoke 3111 and teeth 3112 extending radially from the yoke 3111 towards the rotor 32. Multiple teeth 3112 are arranged along the axis of the rotor 32, and adjacent teeth 3112 define stator slots 3113 that accommodate the winding 312. The winding 312 includes a coil 3121 and a cage 3122 supporting the coil 3121. The winding 312 is at least partially disposed in the stator slots 3113. Exemplarily, the winding 312 is inserted into the stator slots 3113. Coils 3121 belonging to the same phase are connected in series and parallel, and then connected in a delta or Y-shape between phases to form the input and output lines of the motor 30. The coil 3121 is a conductive metal coil, such as copper wire.

[0077] In this embodiment, the retainer 3122 is provided with a filling portion 3123 to fill the gaps between the coils 3121. The filling portion 3123 includes at least a thermally conductive but non-magnetic material. By using a thermally conductive but non-magnetic material to eliminate air between the coils 3121, the air gaps are reduced, so that the multi-turn coils 3121 form a whole with good thermal conductivity, thereby improving the thermal conductivity of the winding 312.

[0078] As shown in Figures 10 and 11, this is a motor of an electric device according to another embodiment of this application. The difference between this motor and the motor 30 disclosed in Figures 5 to 9 is that the motor is configured as an axial magnetic field motor. The following description focuses on the differences between the stator and the stator 31.

[0079] An axial field motor, disc motor, or axial flux motor has a magnetic field direction parallel to the motor shaft. It includes a motor consisting of a rotor disc and a stator, as well as a motor with the rotor disc sandwiched between two stator discs. Taking any single stator as an example...

[0080] The stator includes a stator core 311C and a winding 312C. The stator core 311C includes a yoke 3111C and teeth 3112C extending axially from the yoke 3111C toward a rotor (not shown). Multiple teeth 3112C are arranged along the axis of the rotor (not shown), and adjacent teeth 3112C define stator slots 3113C that accommodate the windings 312C. The windings 312C include coils 3121C and a cage 3122C supporting the coils 3121C. The windings 312C are at least partially disposed in the stator slots 3113C. Exemplarily, the windings 312C are inserted into the stator slots 3113C. Coils 3121C belonging to the same phase are connected in series and parallel, and then connected in a delta or Y-shape between phases to form motor input and output lines. The coils 3121C are coils of conductive metal, such as copper wire.

[0081] The cage 3122C is provided with a filler portion 3123C, which is configured to fill the gaps present inside the winding 312C, and the filler portion 3123C is made of at least a thermally conductive, non-magnetic material. Exemplarily, the gaps include at least the gaps between coils and between the coil and the cage. By using the aforementioned thermally conductive, non-magnetic material, the air between the coils 3121C can be effectively replaced, reducing or eliminating air gaps, thereby forming a thermally conductive, tightly structured whole among the multi-turn coils 3121C, significantly improving the axial and radial thermal conductivity of the winding 312C. The thermally conductive filler material establishes an efficient heat conduction path, enabling rapid heat dissipation from hot spots inside the coil, effectively reducing the local and overall operating temperature of the winding 312C, and improving the power density and operational reliability of the motor. Furthermore, the non-magnetic properties of the filler portion 3123C avoid the generation of additional eddy current losses, ensuring the electrical performance of the winding 312C. In addition, composite materials can enhance the mechanical support and insulation protection between coils, and improve the integrity, vibration resistance and long-term stability of the winding.

[0082] For example, thermally conductive but non-magnetic materials include composite materials composed of organic resins and inorganic fillers. The most commonly used organic resin is epoxy resin, but modified epoxy resins such as polyvinyl butyral, acrylate, and polyurethane are also frequently used. Other types of resins can also be selected, such as phenolic resins, polyimide resins, polyethylene terephthalate, and polyphenylene ether. Inorganic fillers include Al₂O₃, MgO, ZnO, BeO, Si₃N₄, and AlN.

[0083] The stator slot 3113C is provided with an opening 3114C extending axially toward the rotor, and the winding 312C is inserted integrally into the stator slot 3113C through the opening 3114C. In this embodiment, the stator core 311C is provided with an output shaft hole 313C for accommodating the rotor shaft. Teeth 3112C extend axially from the yoke 3111C toward the output shaft hole 313C. A plurality of teeth 3112C are arranged along the axis of the output shaft hole 313C.

[0084] The cage 3122C of winding 312C also includes a support portion 3124C, which at least partially comprises a thermally conductive but non-magnetically conductive material. Optionally, the support portion 3124C at least partially comprises a thermally conductive insulating material. In this embodiment, the support portion 3124C is generally cylindrical, with a quadrilateral cross-section. The support portion 3124C is disposed on the outer periphery of the tooth portion 3112C, which is inserted into the support portion 3124C. Exemplarily, the support portion 3124C has a through hole 3125C that matches the structural shape of the tooth portion 3112C for insertion of the tooth portion 3112C. The through hole 3125C extends axially along the stator core 311C.

[0085] In this embodiment, the opening 3114C on the stator core 311C is an opening of equal width. Exemplarily, the teeth 3112C on the stator core 311C have an equal-width tooth structure. In this embodiment, 12 teeth 3112C are provided, and the teeth 3112C are arranged at 30° intervals in the circumferential direction. The pre-formed winding 312C is arranged along the axial direction of the stator core 311C, allowing the teeth 3112C to enter the support portion 3124C.

[0086] As shown in Figure 12, as the third embodiment of this application, it differs from the motor 30 disclosed in Figures 5 to 8 in that the stator core 311B is different. The following description mainly focuses on the differences between the stator core 311B and the stator core 311.

[0087] In this embodiment, the stator core 311B further includes a slot wedge 314B, which is installed in the stator slot 3113B to prevent the winding from falling out of the stator slot 3113B. The slot wedge 314B is made of magnetic material. In related technologies, the stator core 311B uses an open slot structure, which alters the air gap magnetic field distribution of the motor 30, increasing air gap magnetic field harmonics and eddy current losses in the winding 312, leading to performance degradation of the motor 30. In this embodiment, a magnetically conductive slot wedge 314B is inserted into the opening 3114B of the open slot in the stator core 311B, changing the air gap magnetic field distribution and thus improving the performance of the motor 30. Simultaneously, it prevents the winding from radially falling out of the stator core 311B.

[0088] In some embodiments, the slot wedge 314B comprises ferrite, silicon steel, iron-nickel alloy, and ferronitrile material.

[0089] In this embodiment, a limiting groove is provided in the stator slot 3113B along the axial direction of the stator core 311B, and the slot wedge 314B is inserted into the limiting groove for fixation, thereby limiting the winding 312 inserted into the stator core 311B as a whole in the stator slot 3113B.

[0090] In this embodiment, the opening 3114B on the stator core 311B is an opening of equal width. For example, the stator teeth on the stator core 311B are of equal width.

[0091] In some embodiments, the plurality of slot wedges 314B are independently provided. In some embodiments, the plurality of slot wedges 314B are connected as a whole, which is basically a roller shutter structure and is installed on the stator core 311B as a whole.

[0092] The foregoing has shown and described the basic principles, main features, and advantages of this application. Those skilled in the art should understand that the above embodiments do not limit this application in any way, and all technical solutions obtained by equivalent substitution or equivalent transformation fall within the protection scope of this application.

Claims

1. An electric device, comprising: An electric motor, comprising a stator and a rotor, wherein the rotor rotates about a first axis; The output section is configured to be driven by the power provided by the motor. The stator includes: a stator core and windings; The stator core includes: a yoke and teeth extending from the yoke toward the rotor, a plurality of teeth being arranged circumferentially along the axis of the rotor, and two adjacent teeth defining stator slots for accommodating the windings; The winding includes a coil and a cage supporting the coil. The winding is at least partially disposed in the stator slot. The cage is provided with a filler portion configured to fill gaps present inside the winding. The filler portion includes at least a thermally conductive but non-magnetically conductive material.

2. The electric device according to claim 1, characterized in that, The gap includes at least the gap between the coils and the gap between the coil and the cage.

3. The electric device according to claim 1, characterized in that, The stator slot is provided with an opening; the winding is embedded into the stator slot entirely through the opening.

4. The electric device according to claim 1, characterized in that, The cage includes a support portion disposed on the outer periphery of the teeth, the coil is supported by the support portion, and the filler portion is formed in the support portion.

5. The electric device according to claim 4, characterized in that, The filling portion is formed on the support portion by injection molding.

6. The electric device according to claim 4, characterized in that, After the coil is directly wound and shaped on the support, the material constituting the filling part is filled or applied to the outer periphery of the coil by injection molding.

7. The electric device according to claim 4, characterized in that, The filling part, the supporting part, and the coil are injection molded as a single unit.

8. The electric device according to claim 7, characterized in that, After the coil wire is independently wound and formed, the support part is injection molded around the outer periphery of the formed coil.

9. The electric device according to claim 8, characterized in that, The filling portion is integrally injection molded on the outer periphery of the coil to fill the gaps between the coils.

10. The electric device according to claim 4, characterized in that, The cage further includes a first end face disposed at one axial end of the support portion, the first end face extending radially along the support portion, and a second end face disposed at the other axial end of the support portion, the second end face extending radially along the support portion, and the first end face being connected to the inner side of the yoke portion.

11. The electric device according to claim 1, characterized in that, The slot fill factor of the motor is greater than or equal to 40% and less than or equal to 70%.

12. The electric device according to claim 1, characterized in that, The stator includes a plurality of windings, and the cage of the windings is provided with a connecting part, and the plurality of windings are interconnected through the connecting part.

13. The electric device according to claim 12, characterized in that, The connection restricts the radial and axial movement of the winding relative to the stator core.

14. The electric device according to claim 1, characterized in that, The stator further includes a limiting part, which is connected to the stator core for limiting the radial and axial movement of the winding relative to the stator core.

15. The electric device according to claim 3, characterized in that, The openings on the stator core are configured to be of equal width.

16. An electric motor, comprising: The rotor rotates around the first axis. Stator, including stator core and windings; The stator core includes a yoke and teeth extending from the inside of the yoke, wherein a plurality of teeth are arranged circumferentially along the axis of the rotor, and two adjacent teeth define stator slots for accommodating the windings. The winding includes a coil and a cage supporting the coil. The winding is at least partially disposed in the stator slot. The cage is provided with a filler portion configured to fill gaps present inside the winding. The filler portion includes at least a thermally conductive but non-magnetically conductive material.

17. The motor according to claim 16, characterized in that, The gap includes at least the gap between the coils and the gap between the coil and the cage.

18. The motor according to claim 16, characterized in that, The stator slot is provided with an opening; the winding is embedded into the stator slot as a whole through the opening.

19. The motor according to claim 16, characterized in that, The slot fill factor of the motor is greater than or equal to 40% and less than or equal to 70%.

20. The motor according to claim 16, characterized in that, The cage includes a support portion disposed on the outer periphery of the teeth, the coil is supported by the support portion, and the filler portion is formed in the support portion.

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