Stator assembly for use in motor and assembly method therefor, and motor

Patent metadata

Field	Value
Publication number	US-2024128823-A1
Application number	US-202118555092-A
Country	US
Kind code	A1
Filing date	Apr 12, 2021
Priority date	Apr 12, 2021
Publication date	Apr 18, 2024
Grant date	—

Abstract

The present invention provides a stator assembly for use in a motor and an assembly method therefor. The stator assembly comprises an iron core ( 1 ), comprising a cylindrical iron core body and a plurality of iron core teeth ( 11 ), conductor slots ( 1 h ) for accommodating conductors ( 3 ) being formed between every two iron core teeth ( 11 ) adjacent in the circumferential direction, side walls of each conductor slot ( 1 h ) formed by the iron core teeth ( 11 ) each comprising a flared portion ( 111 ), and the flared portions ( 111 ) being opposite each other in the circumferential direction and gradually getting further away from each other as the two extend towards radial openings of the conductor slots ( 1 h ), and sheet-like insulators ( 2 ), accommodated in the conductor slots ( 1 h ) in a manner of attaching to the peripheral walls of the conductor slots ( 1 h ), the ends of the sheet-like insulators ( 2 ) being disposed at the flared portions ( 111 ). As such, undesired interference between the conductors and the sheet-like insulators does not occur during the insertion of the conductors into the conductor slots. The present invention also provides a motor comprising the stator assembly for use in a motor, which can produce the same beneficial effect.

First claim

1 . A stator assembly for a motor, comprising: an iron core, wherein the iron core includes a cylindrical iron core body and a plurality of iron core teeth, the plurality of iron core teeth protruding from the iron core body along a radial direction of the iron core body and being arranged along a circumferential direction of the iron core body, conductor slots for accommodating conductors being formed between every two iron core teeth adjacent in the circumferential direction, side walls of the conductor slots formed by the iron core teeth having flared portions, and the flared portions being opposite each other in the circumferential direction and diverging from each other as the flared portions extend towards radial openings of the conductor slots; and
sheet-like insulators, wherein the sheet-like insulators are accommodated in the conductor slots in a manner of attaching to peripheral walls of the conductor slots, and ends of the sheet-like insulators are disposed at the flared portions.

2 . The stator assembly according to claim 1 , wherein in a cross section orthogonal to a central axis of the iron core body taken along the radial direction, a contour line of the flared portion extends linearly or curvilinearly.

3 . The stator assembly according to claim 2 , wherein the side walls further comprise equidistant portions adjacent to the flared portions, the equidistant portions being opposite to each other in the circumferential direction and a spacing in the circumferential direction between the equidistant portions being always equal in the radial direction.

4 . The stator assembly according to claim 3 , wherein in the cross section orthogonal to the central axis of the iron core body taken along the radial direction, an angle of an obtuse angle formed by the contour line of the flared portion and a contour line of the equidistant portion is not less than 150 degrees.

5 . The stator assembly according to claim 3 , wherein there is a non-smooth transition or a smooth transition between the flared portion and the equidistant portion, and the sheet-like insulator forms a curved shape at a junction between the flared portion and the equidistant portion.

6 . The stator assembly according to any claim 1 , wherein an end of the iron core tooth at the radial opening of the conductor slot has a slot wedge portion protruding towards the inside of the conductor slot, and the slot wedge portion is adjacent to the flared portion.

7 . The stator assembly according to claim 6 , wherein the ends of the sheet-like insulators extends to a face of the slot wedge portion adjacent to the flared portion.

8 . The stator assembly according to claim 1 , wherein the stator assembly includes conductors, and a plurality of conductors are respectively accommodated and installed in each conductor slot formed by the iron core.

9 . The stator assembly according to claim 8 , wherein the conductor is a wave winding.

10 . An assembly method for a stator assembly for use in a motor, the assembly method comprising the following steps:
providing a stator comprising an iron core, wherein the iron core includes a cylindrical iron core body and a plurality of iron core teeth, the plurality of iron core teeth protruding from the iron core body along a radial direction of the iron core body and being arranged along a circumferential direction of the iron core body, conductor slots for accommodating conductors being formed between every two iron core teeth adjacent in the circumferential direction, side walls of the conductor slots formed by the iron core teeth having flared portions, and the flared portions being opposite each other in the circumferential direction and diverging from each other as the flared portions extend towards radial openings of the conductor slots, wherein in a cross section orthogonal to a central axis of the iron core body taken along the radial direction, a contour line of the flared portion extends linearly or curvilinearly, wherein the side walls further comprise equidistant portions adjacent to the flared portions, the equidistant portions being opposite to each other in the circumferential direction and a spacing in the circumferential direction between the equidistant portions being always equal in the radial direction; and putting a sheet-like insulator into the conductor slot, wherein the sheet-like insulator curves at an interface of the flared portion and the equidistant portion of the side wall of the conductor slot, the sheet-like insulator is attached to the peripheral wall of the conductor slot, and an end of the sheet-like insulator is disposed at the flared portion; and inserting the conductor into the conductor slot along the radial direction.

11 . A motor, comprising a stator assembly having an iron core, wherein the iron core includes a cylindrical iron core body and a plurality of iron core teeth, the plurality of iron core teeth protruding from the iron core body along a radial direction of the iron core body and being arranged along a circumferential direction of the iron core body, conductor slots for accommodating conductors being formed between every two iron core teeth adjacent in the circumferential direction, side walls of the conductor slots formed by the iron core teeth having flared portions, and the flared portions being opposite each other in the circumferential direction and diverging from each other as the flared portions extend towards radial openings of the conductor slots; and
sheet-like insulators, wherein the sheet-like insulators are accommodated in the conductor slots in a manner of attaching to peripheral walls of the conductor slots, and ends of the sheet-like insulators are disposed at the flared portions.

12 . The motor according to claim 11 , wherein in a cross section orthogonal to a central axis of the iron core body taken along the radial direction, a contour line of the flared portion extends linearly or curvilinearly.

13 . The motor according to claim 12 , wherein the side walls further comprise equidistant portions adjacent to the flared portions, the equidistant portions being opposite to each other in the circumferential direction and a spacing in the circumferential direction between the equidistant portions being always equal in the radial direction.

14 . The motor according to claim 13 , wherein in the cross section orthogonal to the central axis of the iron core body taken along the radial direction, an angle of an obtuse angle formed by the contour line of the flared portion and a contour line of the equidistant portion is not less than 150 degrees.

15 . The motor according to claim 13 , wherein there is a non-smooth transition or a smooth transition between the flared portion and the equidistant portion, and the sheet-like insulator forms a curved shape at a junction between the flared portion and the equidistant portion.

16 . The motor according to claim 11 , wherein an end of the iron core tooth at the radial opening of the conductor slot has a slot wedge portion protruding towards the inside of the conductor slot, and the slot wedge portion is adjacent to the flared portion.

17 . The motor according to claim 16 , wherein the ends of the sheet-like insulators extend to a face of the slot wedge portion adjacent to the flared portion.

18 . The motor according to claim 11 , wherein the stator assembly includes conductors, and a plurality of conductors are respectively accommodated and installed in each conductor slot formed by the iron core.

19 . The motor according to claim 18 , where

Assignees

• Li Zhihao
• Schaeffler Technologies Ag

Inventors

• Li Zhihao
• Liang Jie

Classifications

• H02K15/10

  Applying solid insulation to windings, stators or rotors, e.g. applying insulating tapes · CPC title

• H02K15/062

  Windings in slots; Salient pole windings · CPC title

• H02K3/487

  Slot-closing devices · CPC title

• H02K1/165

  Shape, form or location of the slots · CPC title

• H02K3/345 Primary

  between conductor and core, e.g. slot insulation · CPC title