Stator slot wedge, slot wedge injection mold, and stator

Abstract

A stator slot wedge, a slot wedge injection mold, and a stator. The stator slot wedge provided in the present application comprises magnetically conductive portions (10). Each magnetically conductive portion (10) comprises first insulating layers (2) and a plurality of magnetically conductive bodies (1), wherein the plurality of magnetically conductive bodies (1) are sequentially arranged at intervals, and each magnetically conductive body (1) comprises a plurality of magnetically conductive sheets (11) which are sequentially stacked and fixed; the plurality of magnetically conductive sheets (11) are formed by means of stacking using a stacking and riveting process, thereby forming each magnetically conductive body (1); and each first insulating layer (2) is filled between two adjacent magnetically conductive bodies (1).

Description

Stator slot wedge, slot wedge injection mold and stator

[0001] This application claims priority to Chinese Patent Application No. 202411899279.1, filed with the Chinese Patent Office on December 23, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This application relates to the field of motor technology, for example to a stator slot wedge, a slot wedge injection mold, and a stator. Background Technology

[0003] The magnetic conductors in the stator slot wedge are typically constructed by stacking and fixing multiple magnetic sheets. Each magnetic sheet has an insulating film on both sides along its thickness direction to ensure insulation between adjacent sheets, allowing eddy current loops to form only within each sheet. However, when multiple magnetic sheets are stacked and fixed using a riveting process, the insulating film at the riveting points between adjacent sheets can be damaged, causing magnetic conduction between them. This significantly increases the eddy current loop path, thereby increasing eddy current losses and reducing motor efficiency. Summary of the Invention

[0004] This application provides a stator slot wedge, a slot wedge injection mold, and a stator to avoid magnetic conduction between magnetic conductive bodies formed by stacking and riveting, thereby reducing eddy current loop paths, lowering eddy current losses, and improving motor efficiency.

[0005] This application provides a stator slot wedge, the stator slot wedge including a magnetically conductive portion, the magnetically conductive portion comprising:

[0006] A multi-segment magnetically conductive body, wherein the multiple segments are arranged sequentially at intervals, and each segment comprises multiple sequentially stacked and fixed magnetically conductive sheets, which are stacked and formed using a riveting process to form the magnetically conductive body; and

[0007] A first insulating layer is filled between two adjacent sections of the magnetically conductive body.

[0008] As an option, the first insulating layer may be insulating paper, or the first insulating layer may be insulating adhesive, or the first insulating layer may be integrally injection molded between two adjacent sections of the magnetically conductive body.

[0009] As an optional solution, each of the magnetic conductive sheets is provided with an insulating film on both sides opposite to each other along its thickness direction. Among two adjacent magnetic conductive sheets that are stacked and fixed, one of them is provided with a rivet protrusion and the other is provided with a rivet groove. The rivet protrusion is inserted and fixed in the rivet groove.

[0010] In two adjacent magnetic conductive bodies, the outermost rivet protrusion in one magnetic conductive body is misaligned with the outermost rivet groove in the other magnetic conductive body.

[0011] As an optional solution, in two adjacent magnetically conductive bodies, the orientation of the rivet protrusions on each magnetically conductive sheet in one magnetically conductive body is the same as the orientation of the rivet protrusions on each magnetically conductive sheet in the other magnetically conductive body.

[0012] Alternatively, in two adjacent magnetically conductive bodies, the orientation of the rivet protrusions on each magnetically conductive sheet in one magnetically conductive body is opposite to the orientation of the rivet protrusions on each magnetically conductive sheet in the other magnetically conductive body.

[0013] Alternatively, the thickness of the first insulating layer may be greater than the height of the rivet protrusion.

[0014] As an optional solution, the magnetically conductive part further includes:

[0015] The second insulating layer is provided on the outer wall of each section of the magnetically conductive body.

[0016] Alternatively, the second insulating layer may be insulating paper, or the second insulating layer may be integrally injection molded onto the outer wall of each segment of the magnetically conductive body.

[0017] As an optional embodiment, the stator slot wedge includes two magnetically conductive portions arranged at intervals along the width direction of the stator slot wedge.

[0018] This application also provides a slot wedge injection mold, wherein the stator slot wedge further includes a non-magnetic portion, and the slot wedge injection mold is configured to integrally injection mold the non-magnetic portion of the stator slot wedge as described above onto the magnetic portion.

[0019] This application also provides a stator, including a stator core and a stator slot wedge as described above, wherein a plurality of open slots are spaced apart along the circumference of the stator core, and a stator slot wedge is disposed in each of the open slots. Attached Figure Description

[0020] Figure 1 is a schematic diagram of the stator provided in Embodiment 1 of this application;

[0021] Figure 2 is a schematic diagram of the stator slot wedge provided in Embodiment 1 of this application;

[0022] Figure 3 is a schematic diagram of the magnetic conductive part of the stator slot wedge provided in Embodiment 1 of this application;

[0023] Figure 4 is a schematic diagram of the first structure of the magnetic conductive sheet provided in Embodiment 1 of this application;

[0024] Figure 5 is a schematic diagram of the second structure of the magnetic conductive sheet provided in Embodiment 1 of this application;

[0025] Figure 6 is a schematic diagram of the third structure of the magnetic conductive sheet provided in Embodiment 1 of this application;

[0026] Figure 7 is a schematic diagram of the fourth structure of the magnetic conductive sheet provided in Embodiment 1 of this application;

[0027] Figure 8 is a schematic diagram of the first partial structure of the magnetic conductive part of the stator slot wedge provided in Embodiment 1 of this application;

[0028] Figure 9 is a first partial structural cross-sectional view of the magnetic conductive part of the stator slot wedge provided in Embodiment 1 of this application;

[0029] Figure 10 is a partial exploded view of the magnetic conductive part of the stator slot wedge provided in Embodiment 1 of this application;

[0030] Figure 11 is a second partial structural cross-sectional view of the magnetic conductive part of the stator slot wedge provided in Embodiment 1 of this application;

[0031] Figure 12 is a third partial structural cross-sectional view of the magnetic conductive part of the stator slot wedge provided in Embodiment 1 of this application;

[0032] Figure 13 is a partial structural schematic diagram of the stator provided in Embodiment 2 of this application;

[0033] Figure 14 is a structural schematic diagram of the slot wedge injection mold provided in Embodiment 3 of this application;

[0034] Figure 15 is a partial structural schematic diagram of the slot wedge injection mold provided in Embodiment 3 of this application.

[0035] In the diagram: 100, stator slot wedge; 200, stator core; 201, open slot; 10, magnetic conductive part; 20, non-magnetic conductive part; 1, magnetic conductive body; 11, magnetic conductive sheet; 111, insulating film; 112, rivet protrusion; 113, rivet groove; 2, first insulating layer; 3, second insulating layer; 300, slot wedge injection mold; 310, mold cavity; 320, separator. Detailed Implementation

[0036] The technical solution of this application will be described below with reference to the accompanying drawings and embodiments.

[0037] In the description of this application, unless otherwise specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two elements or the interaction between two elements. The specific meaning of the above terms in this application can be understood according to the specific circumstances.

[0038] In this application, unless otherwise specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0039] In the description of this embodiment, the terms "upper," "lower," "left," and "right," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application. In addition, the terms "first" and "second" are used only for distinction in description and have no special meaning.

[0040] Example 1

[0041] As shown in Figure 1, this embodiment provides a stator, which includes a stator core 200 and a stator slot wedge 100. The stator core 200 has a plurality of open slots 201 spaced apart along its circumference, and each open slot 201 is provided with a stator slot wedge 100.

[0042] This application also provides a stator that, by applying the aforementioned stator slot wedge, avoids magnetic conduction between the magnetic conductive bodies formed by the stacking and riveting process, thereby reducing eddy current loop paths, lowering eddy current losses, and improving motor efficiency.

[0043] As shown in Figures 1 and 2, the stator slot wedge 100 provided in this embodiment seals the top opening of the open slot 201. The stator slot wedge 100 includes a non-magnetic part 20 and a magnetic part 10. The outer wall of the magnetic part 10 engages with the inner wall of the open slot 201. The non-magnetic part 20 is integrally injection molded onto the magnetic part 10, thereby cutting off the magnetic connection between the inner wall of the magnetic part 10 and the slot wall of the open slot 201. Since the slot of the stator core 200 has an open slot 201 structure, it facilitates winding unwinding. Furthermore, the magnetic part 10 in the stator slot wedge 100 and the open slot 201 work together to function as a semi-open slot, thus improving the electromagnetic performance of the stator. In addition, the non-magnetic part 20 in the stator slot wedge 100 serves to limit the winding, eliminating the need for the entire stator slot wedge 100 to be magnetically conductive, reducing eddy current phenomena, and thus improving motor efficiency. Furthermore, by integrally injection molding the non-magnetic part 20 onto the magnetic part 10, this embodiment reduces the processing difficulty and cost of the entire stator slot wedge 100, and also improves the bonding strength between the non-magnetic part 20 and the magnetic part 10, thereby improving the structural strength of the entire stator slot wedge 100.

[0044] Optionally, in this embodiment, as shown in Figures 1 and 2, the stator slot wedge 100 includes two magnetically conductive portions 10 spaced apart along the width direction of the stator slot wedge 100. The outer side wall of each magnetically conductive portion 10 is engaged with the inner side wall of the corresponding side of the opening slot 201. This arrangement allows the stator slot wedge 100 to better function as a semi-open slot, improving the electromagnetic performance of the stator. Furthermore, this arrangement ensures that both sides of the stator slot wedge 100 along its width direction are engaged with the inner side wall of the opening slot 201, guaranteeing the reliability and stability of the stator slot wedge 100's engagement and positioning within the opening slot 201.

[0045] In one embodiment, the magnetic conductive part of the stator slot wedge is typically constructed by stacking and fixing multiple magnetic conductive sheets, with an insulating film provided on both opposite sides along the thickness direction of each sheet. This ensures that adjacent magnetic conductive sheets are insulated from each other, allowing the eddy current loop to form only within each sheet. However, when multiple magnetic conductive sheets are stacked and fixed using a riveting process, the insulating film at the riveting points between adjacent sheets can be damaged, causing magnetic conduction between them. This significantly increases the eddy current loop path, thereby increasing eddy current losses and reducing motor efficiency.

[0046] To address the aforementioned problems, as shown in Figures 2-5, the magnetically conductive part 10 provided in this embodiment includes a first insulating layer 2 and multiple magnetically conductive body segments 1. These segments are arranged at intervals, and each segment includes multiple magnetically conductive sheets 11 stacked and fixed sequentially. The segments are arranged at intervals along the radial direction of the stator core 200, and each segment includes multiple magnetically conductive sheets 11 stacked and fixed sequentially along the radial direction of the stator core 200. The multiple magnetically conductive sheets 11 are stacked and formed using a riveting process to form the magnetically conductive body 1. The first insulating layer 2 is filled between adjacent segments of the magnetically conductive body 1. By filling the space between adjacent segments of the magnetically conductive body 1 with the first insulating layer 2, the magnetically conductive part 10 provided in this embodiment avoids magnetic conduction between the stacked magnetically conductive body segments 1, thereby reducing eddy current loop paths, lowering eddy current losses, and improving motor efficiency. Optionally, in this embodiment, the magnetic sheet 11 is a silicon steel sheet, and each silicon steel sheet has an insulating film 111 disposed on both opposite sides along its thickness direction. Each magnetic sheet 11 has an insulating film 111 disposed on both opposite sides along its thickness direction.

[0047] Optionally, in this embodiment, the first insulating layer 2 is integrally injection molded between two adjacent magnetically conductive body sections 1. This arrangement not only ensures the structural strength of the entire magnetically conductive part 10 but also facilitates processing, reducing processing difficulty and cost. In this embodiment, when the non-magnetically conductive part 20 is integrally injection molded onto the magnetically conductive part 10, the first insulating layer 2 can be simultaneously integrally injection molded between two adjacent magnetically conductive body sections 1. In other embodiments, the first insulating layer 2 can be insulating paper. In other embodiments, the first insulating layer 2 can also be insulating adhesive.

[0048] In this embodiment, as shown in FIG2, the magnetically conductive part 10 further includes a second insulating layer 3. A second insulating layer 3 is provided on the contact surface between the outer wall of each segment of the magnetically conductive body 1 and the inner wall of the opening groove 201. The second insulating layer 3 is provided on the outer wall of each segment of the magnetically conductive body 1. This arrangement effectively prevents magnetic conduction at the engagement point between the magnetically conductive body 1 and the stator core 200, thereby reducing eddy current losses in both the magnetically conductive body 1 and the stator core 200.

[0049] The second insulating layer 3 is integrally injection molded onto the outer wall of each segment of the magnetically conductive body 1. Optionally, in this example, the second insulating layer 3 is integrally injection molded onto the contact surface between each segment of the magnetically conductive body 1 and the stator core 200. This arrangement not only ensures the structural strength of the entire magnetically conductive part 10 but also facilitates processing, reducing processing difficulty and cost. In this embodiment, when the non-magnetically conductive part 20 is integrally injection molded onto the magnetically conductive part 10, the second insulating layer 3 can be simultaneously integrally injection molded onto the contact surface between each segment of the magnetically conductive body 1 and the stator core 200. Optionally, in this embodiment, the non-magnetically conductive part 20 can wrap around the contact surface between the magnetically conductive body 1 and the stator core 200 during injection molding, making the second insulating layer 3 a part of the non-magnetically conductive part 20, thus making processing more convenient.

[0050] In this embodiment, as shown in Figures 4 to 7, among two adjacent stacked and fixed magnetic sheets 11, one has a rivet protrusion 112 and the other has a rivet groove 113. The rivet protrusion 112 is inserted and fixed in the rivet groove 113, thereby realizing the stacking and riveting fixation between the two magnetic sheets 11. In each magnetic sheet 11, the rivet protrusion 112 is provided on one side along its thickness direction, and the rivet groove 113 is provided on the other side along its thickness direction. In two adjacent magnetic body segments 1, the outermost rivet protrusion 112 in one magnetic body 1 and the outermost rivet groove 113 in the other magnetic body 1 are staggered.

[0051] In an optional embodiment of this invention, as shown in Figures 8 to 11, in two adjacent magnetically conductive bodies 1, the orientation of the rivet protrusions 112 on each magnetic sheet 11 of one magnetically conductive body 1 is the same as the orientation of the rivet protrusions 112 on each magnetic sheet 11 of the other magnetically conductive body 1. Furthermore, the outermost rivet protrusion 112 in one magnetically conductive body 1 is misaligned with the outermost rivet groove 113 in the other magnetically conductive body 1. This arrangement avoids the outermost rivet protrusion 112 of one magnetically conductive body 1 being inserted into the outermost rivet groove 113 of the other magnetically conductive body 1, thus preventing magnetic connection between the two adjacent magnetically conductive bodies 1 through rivets. It also creates a certain gap between the two adjacent magnetically conductive bodies 1 due to the outermost rivet protrusion 112, facilitating the integral injection molding of the first insulating layer 2 within the gap between the two adjacent magnetically conductive bodies 1. Optionally, as shown in Figures 8-10, in two adjacent magnetically conductive bodies 1, each magnetically conductive sheet 11 in one magnetically conductive body 1 has two rivet protrusions 112 spaced apart on one side along its thickness direction, and each magnetically conductive sheet 11 has two rivet grooves 113 spaced apart on the other side along its thickness direction, with the two rivet protrusions 112 and the two rivet grooves 113 facing each other. In the other magnetically conductive body 1, each magnetically conductive sheet 11 has one rivet protrusion 112 spaced apart on one side along its thickness direction, and each magnetically conductive sheet 11 has one rivet groove 113 spaced apart on the other side along its thickness direction, which faces the rivet protrusion 112. Optionally, as shown in Figure 11, in two adjacent magnetically conductive bodies 1, each magnetically conductive sheet 11 in one magnetically conductive body 1 has two rivet protrusions 112 spaced apart on one side along its thickness direction, and each magnetically conductive sheet 11 has one rivet groove 113 spaced apart on the other side along its thickness direction, which faces the rivet protrusion 112. A rivet protrusion 112 is provided on the side, and a rivet groove 113 is provided on the other side of each magnetic sheet 11 along its thickness direction, which is directly opposite to the rivet protrusion 112. In another magnetic body 1, each magnetic sheet 11 is provided with a rivet protrusion 112 on one side along its thickness direction, and a rivet groove 113 is provided on the other side along its thickness direction, which is directly opposite to the rivet protrusion 112. In this embodiment, the number of rivet protrusions 112 and rivet grooves 113 on each magnetic sheet 11 is not limited, as long as it is ensured that in two adjacent magnetic body segments 1, the position of the rivet protrusion 112 on each magnetic sheet 11 in one magnetic body 1 is staggered with the position of the rivet groove 113 on each magnetic sheet 11 in the other magnetic body 1.

[0052] In another optional embodiment of this example, as shown in FIG12, in two adjacent magnetically conductive bodies 1, the orientation of the rivet protrusions 112 on each magnetic sheet 11 in one magnetically conductive body 1 is opposite to the orientation of the rivet protrusions 112 on each magnetic sheet 11 in the other magnetically conductive body 1, and the outermost rivet protrusion 112 in one magnetically conductive body 1 is misaligned with the outermost rivet groove 113 in the other magnetically conductive body 1. This arrangement avoids the outermost rivet protrusion 112 in one magnetically conductive body 1 being inserted into the outermost rivet groove 113 in the other magnetically conductive body 1, thereby preventing the two adjacent magnetically conductive bodies 1 from achieving magnetic communication through rivets. It also creates a certain gap between the two adjacent magnetically conductive bodies 1 due to the outermost rivet protrusion 112, thus facilitating the integral injection molding filling of the first insulating layer 2 in the gap between the two adjacent magnetically conductive bodies 1. Furthermore, the aforementioned configuration eliminates the need for rivets at the contact points between some adjacent magnetically conductive body segments 1. This allows adjacent segments 1 to be directly insulated by their own insulating film 111, eliminating the need for additional injection molding to fill the first insulating layer 2. This simplifies the structure and reduces the splicing gap between adjacent segments 1. For example, as shown in Figure 12, when four segments 1 are spliced, only one adjacent segment 1 requires injection molding to fill the first insulating layer 2. Similarly, when five segments 1 are spliced, only two adjacent segments require injection molding to fill the first insulating layer 2.

[0053] Optionally, in this embodiment, as shown in Figures 9, 11, and 12, the thickness of the first insulating layer 2 is greater than the height of the rivet protrusion 112. This arrangement effectively ensures the insulation effect between adjacent sections of the magnetically conductive body 1.

[0054] Example 2

[0055] The magnetic conductive part 10 provided in this embodiment is basically the same as that in Embodiment 1. The difference between the magnetic conductive part 10 provided in this embodiment and that in Embodiment 1 is:

[0056] As shown in Figure 13, in this embodiment, the second insulating layer 3 is insulating paper. Optionally, insulating paper can be attached to the contact surface between the outer wall of the magnetically conductive body 1 and the inner wall of the opening groove 201, or the insulating paper can be laid at the contact point between the opening groove 201 and the outer wall of the magnetically conductive body 1, as long as insulating paper is present at the contact surface between the outer wall of the magnetically conductive body 1 and the inner wall of the opening groove 201.

[0057] Example 3

[0058] As shown in Figures 14 and 15, this embodiment also provides a slot wedge injection mold 300, which is configured to integrally injection mold the non-magnetic portion 20 of the stator slot wedge 100 onto the magnetic portion 10. The slot wedge injection mold 300 provided in this embodiment reduces eddy current losses, improves motor efficiency, and ensures the structural strength of the entire stator slot wedge 100 by integrally injection molding the non-magnetic portion 20 of the stator slot wedge 100 onto the magnetic portion 10.

[0059] In this embodiment, as shown in FIG14, the slot wedge injection mold 300 is provided with a mold cavity 310 inside. The outer contour of the mold cavity 310 is adapted to the outer contour of the stator slot wedge 100. First, the multi-segment magnetic conductive body 1 is placed in the mold cavity 310, and the adhesive is injected into the mold cavity 310, so that the adhesive solidifies into the first insulating layer 2, the second insulating layer 3 and the non-magnetic part 20 at the appropriate position. After the adhesive is completely solidified, the processed stator slot wedge 100 can be demolded.

[0060] Optionally, in this embodiment, as shown in FIG15, a separator 320 is provided in the mold cavity 310. The separator 320 is configured to separate two adjacent magnetic conductive body 1, thereby ensuring that a gap is formed between the two adjacent magnetic conductive body 1, so as to facilitate the injection molding of the first insulating layer 2 between the two adjacent magnetic conductive body 1.

Claims

1. A stator slot wedge, wherein, The stator slot wedge includes a magnetically conductive part (10), which includes: A multi-segment magnetically conductive body (1) is provided, wherein the multi-segment magnetically conductive body (1) is arranged sequentially at intervals, and each segment of the magnetically conductive body (1) includes a plurality of sequentially stacked and fixed magnetically conductive sheets (11), wherein the plurality of magnetically conductive sheets (11) are stacked and formed by a riveting process to form the magnetically conductive body (1); and A first insulating layer (2) is filled between two adjacent sections of the magnetically conductive body (1).

2. The stator slot wedge according to claim 1, wherein, The first insulating layer (2) is insulating paper, or the first insulating layer (2) is insulating adhesive, or the first insulating layer (2) is integrally injection molded between two adjacent sections of the magnetic conductive body (1).

3. The stator slot wedge according to claim 1 or 2, wherein, Each of the magnetic conductive sheets (11) has an insulating film (111) on both sides opposite to each other along its thickness direction. Among two adjacent magnetic conductive sheets (11) that are stacked and fixed, one of them has a rivet protrusion (112) and the other has a rivet groove (113). The rivet protrusion (112) is inserted and fixed in the rivet groove (113). In two adjacent magnetic conductive bodies (1), the outermost rivet protrusion (112) in one magnetic conductive body (1) is staggered with the outermost rivet groove (113) in the other magnetic conductive body (1).

4. The stator slot wedge according to claim 3, wherein, In two adjacent magnetic conductive bodies (1), the orientation of the rivet protrusion (112) on each magnetic conductive sheet (11) in one magnetic conductive body (1) is the same as the orientation of the rivet protrusion (112) on each magnetic conductive sheet (11) in the other magnetic conductive body (1); Alternatively, in two adjacent magnetic bodies (1), the orientation of the rivet protrusion (112) on each magnetic sheet (11) in one magnetic body (1) is opposite to the orientation of the rivet protrusion (112) on each magnetic sheet (11) in the other magnetic body (1).

5. The stator slot wedge according to claim 3, wherein, The thickness of the first insulating layer (2) is greater than the height of the rivet protrusion (112).

6. The stator slot wedge according to claim 1 or 2, wherein, The magnetic conductive part (10) further includes: The second insulating layer (3) is provided on the outer side wall of each section of the magnetically conductive body (1).

7. The stator slot wedge according to claim 6, wherein, The second insulating layer (3) is insulating paper, or the second insulating layer (3) is integrally injection molded onto the outer wall of each section of the magnetic conductive body (1).

8. The stator slot wedge according to claim 7, wherein, The stator slot wedge includes two magnetically conductive portions (10) spaced apart along the width direction of the stator slot wedge.

9. A groove wedge injection mold, wherein, The stator slot wedge also includes a non-magnetic part (20), and the slot wedge injection mold is configured to integrally inject the non-magnetic part (20) of the stator slot wedge according to any one of claims 1 to 8 onto the magnetic part (10).

10. A stator comprising a stator core (200) and a stator slot wedge (100) according to any one of claims 1 to 8, wherein a plurality of open slots (201) are spaced apart along the circumference of the stator core (200), and a stator slot wedge (100) is disposed in each of the open slots (201).

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