Patent Application
20240333047
The disclosure relates to a strip stator core, a stator assembly comprising the strip stator core, and a motor comprising the stator assembly.
In the process of manufacturing iron cores, the end face of the iron core needs to be coated to protect the iron core. Many factories adopt manual spraying, but this method had high labor intensity, poor working environment, and low production efficiency. With technological innovation, electrophoretic coating processes are used for the surface coating of the iron core, which can greatly improve work efficiency and working environment. At present, cathodic electrophoretic coating technology is commonly used for motor stator and rotor cores, that is, immersing conductive coated materials in a certain concentration of cathodic electrophoretic coating tank as the cathode, and placing a corresponding anode in the tank. A certain amount of direct current is applied between the cathode and the anode, so that a uniform and water insoluble coating film forms on the coated materials. Electrophoretic coating is widely used for coating processing on the surface of motor stator and rotor cores due to its advantages of high efficiency, high quality (uniform and flat appearance of paint film, no abnormalities, etc.), and safety.
To save manufacturing costs, improve winding efficiency, and meet the requirements of higher slot filling rate, strip stator cores are generally adopted for motor design and manufacturing. When using strip stator cores to manufacture motors, the strip stator cores are rolled, electrophoretically coated and processed into circular stator cores. The strip stator core includes a plurality of interconnected stator core units 1A. The outer surfaces of all the interconnected stator core units 1A are fully covered with an electrophoretic protective film 2A, which can better protect the stator core. However, after winding the strip stator core into a circular stator core, it is found that the roundness of the circular stator core is not up to the standard. The stator core is difficult to close, and the inner and outer diameters of the annular stator core also exceed the design requirements. After testing and comparison, it is found that the important dimensions of the circular stator core obtained by rolling the same structured strip stator core without electrophoretic coating meet the design requirements. The testing results can be seen in Table 1. Table 1 shows the comparison of the dimensions of the circular stator core obtained by electrophoretic rolling and without electrophoretic rolling of a certain stator core.
Based on the above descriptions, the outer surfaces of the interconnected stator core units 1A are fully covered with electrophoretic protection film 2A, that is, the electrophoretic protection film 2A is fully coated on the yoke 11A and tooth 12A of each stator core unit 1A. As shown in
The dashed line in
The disclosure provides a strip stator core, comprising: a plurality of interconnected stator core units, each of the plurality of stator core units comprising a yoke and a tooth part protruding from an inner side or an outer side of the yoke. The tooth part comprises an outer surface partially or completely covered with an electrophoretic protective film and yokes of the plurality of interconnected stator core units are coiled to form a ring.
In a class of this embodiment, the tooth part comprises a crown and a root; and the crown and a part of the root connected to the crown are coated with the electrophoretic protective film.
In a class of this embodiment, a boundary line L between the electrophoretic protective film and the root is a middle line of the root.
In a class of this embodiment, each of the plurality of stator core units comprises a plurality of silicon steel laminates.
In a class of this embodiment, two yokes of every two adjacent stator core units are connected through a connecting bar; and the connecting bar is located on one end of the yoke away from the tooth part.
In a class of this embodiment, a first groove is disposed on a first side of the connecting bar and between two yokes of two adjacent stator core units; a second groove is disposed on a second side of the connecting bar and between the two yokes of the two adjacent stator core units; and the first groove and the second groove are both arc-shaped.
In a class of this embodiment, the yoke of a head of the plurality of stator core units comprises a male buckle, the yoke of a tail of the plurality of stator core units comprises a female buckle matched with the male buckle.
In a class of this embodiment, the yoke of a part of the plurality of stator core units comprises a screw hole.
In another aspect, the disclosure provides a stator assembly, comprising an end insulation, a coil winding, and the above-mentioned strip stator core.
Still, the disclosure provides a motor, comprising the above-mentioned stator assembly, a rotor assembly, and a housing.
The following advantages are associated with the strip stator core of the disclosure.
The outer surface of the tooth part of the stator core units is covered with a layer of electrophoretic protective film, while the yoke of the stator core units is not covered with the electrophoretic protective film, so that the external dimensions of the yoke of the stator core units are not changed. This can effectively prevent the size deviation of the annular stator core after the strip stator core is rolled, effectively improve the qualification rate of the stator core, reduce the material scrap rate, and thus reduce the manufacturing cost of the motor.
To further illustrate the disclosure, embodiments detailing a strip stator core are described below. It should be noted that the following embodiments are intended to describe and not to limit the disclosure.
As shown in
The tooth part 12 comprises a crown 121 and a root 122; and the crown 121 and a part of the root 122 connected to the crown 121 are coated with the electrophoretic protective film 2. Specifically, a boundary line L between the electrophoretic protective film 2 and the root 122 is the middle line of the root 122. This ensures the anti-corrosion protection effect for the stator core, and the reasonable layout of the area of the electrophoretic protection film 2 improves the electrophoretic efficiency, saves processing time of the strip stator core, and reduces processing costs.
Each of the plurality of stator core units 1 comprises a plurality of silicon steel laminates. The processing technology of the silicon steel laminates is mature and the manufacturing cost is low.
The yokes 11 of every two adjacent stator core units 1 are connected through a connecting bar 3; and the connecting bar is located on one end of the yoke 11 away from the tooth part 12. A first groove 4 is disposed on a first side of the connecting bar 3 and between two yokes of two adjacent stator core units 1; a second groove 5 is disposed on a second side of the connecting bar 3 and between the two yokes of the two adjacent stator core units 1; and the first groove 4 and the second groove 5 are both arc-shaped.
The yoke of a head of the plurality of stator core units 1 comprises a male buckle 111, the yoke of a tail of the plurality of stator core units 1 comprises a female buckle 112 matched with the male buckle.
After the strip stator core is rolled into a circular shape, the male buckle 111 on the head stator core unit 1 is embedded in the female buckle 112 on the tail stator core unit 1, maintaining the shape of the circular stator core. The structure is simple and reliable, easy to install.
The yoke 11 of a part of the plurality of stator core units 1 comprises a screw hole 113, thus facilitating the strip stator core to be installed on a motor.
The disclosure also provides a stator assembly, comprising an end insulation, a coil winding, and the abovementioned strip stator core.
The disclosure further provides a motor, comprising the abovementioned stator assembly, a rotor assembly, and a housing.
It will be obvious to those skilled in the art that changes and modifications may be made, and therefore, the aim in the appended claims is to cover all such changes and modifications.
| Number | Date | Country | Kind |
|---|---|---|---|
| 202123251531.2 | Dec 2021 | CN | national |
This application is a continuation-in-part of International Patent Application No. PCT/CN2022/079845 with an international filing date of Mar. 9, 2022, designating the United States, now pending, further claims foreign priority benefits to Chinese Patent Application No. 202123251531.2 filed Dec. 22, 2021. The contents of all of the aforementioned applications, including any intervening amendments thereto, are incorporated herein by reference. Inquiries from the public to applicants or assignees concerning this document or the related applications should be directed to: Matthias Scholl P. C., Attn.: Dr. Matthias Scholl Esq., 245 First Street, 18th Floor, Cambridge, MA 02142.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/CN2022/079845 | Mar 2022 | WO |
| Child | 18739254 | US |
