Background technology
Draining pump be widely used in production, the drainage equipment in each field of living.For example, the indoor set of ceiling type air-conditioning promptly need utilize draining pump.When air-conditioner operation; Because the cooling meeting of air generates a large amount of condensed waters on the surface of heat exchanger; When water gathers certain degree, can drop onto in the condensate draining of heat exchanger below, need in drip tray that therefore draining pump is installed and condensed water is discharged to outdoor.Usually,, require draining pump that certain flow and lift are arranged, and owing to the requirement of environment for use to noise, the operating noise of draining pump also to be limited in certain scope according to the difference of application demand.
Can adopt dc brushless motor to drive the pump housing in the prior art to constitute draining pump.The typical structure of existing dc brushless motor as shown in Figure 1, this motor comprises electric machine casing, stator module 104, rotor assembly and motor shaft 101.Stator module 104 is made up of stator core, stator insulation and coil windings.Rotor assembly is made up of rotor field spider 105 and rotor magnetic steel 106.Electric machine casing specifically comprises bottom end cover 103 and upper end cover 102; Fix this stator module 104 between bottom end cover 103 and the upper end cover 102; Motor shaft 101 passes bottom end cover 103 and stretches out downwards, and motor shaft 101 rotatably is fixed on upper end cover 102 and bottom end cover 103 places through parts such as bearing, spring bearer plate, oily cotton and glands.The outside of motor shaft 101 is arranged with rotor field spider 105 and rotor magnetic steel 106 etc., and is rotatable in stator module 104.Upper end cover 102 inboards also can form the circuit board chamber, are used to place circuit board 107.
The coil of existing dc brushless motor all has more than one coil, adopts centralized winding, therefore is difficult to adopt the embedding structure of the independent coil of in the past single-phase motor with cup rotor or electromagnetically operated valve; Tradition adopts the plastic packaging motor coil of embedding structure, and its endoporus must carry out grinding, has increased machining period, and has produced amounts of dust in the course of processing, pollutes surrounding environment.So prior art adopts twice following injection moulding mode to assemble the manufacturing stator module usually.
At first laminate and form stator core shown in Figure 3 by a plurality of stator punchings shown in Figure 2; Comprise the stator tooth 108 that is used for winding around in the stator core; The stator slot 109 of stator tooth 108 both sides links to each other with the axis hole 111 of stator core through notch 110, makes things convenient for winding around; Then carry out the injection moulding first time, make stator core insulation, the face shaping of injection molding body and the shape of stator core are complementary; Winding around more subsequently; Carry out the injection moulding second time, the plastic back of coil is formed stator module.
There is following defective in the stator module that above-mentioned technology assembling is made: twice injection moulding interface place can leave the slit; Particularly after the stator core integral molded plastic first time; Twice injected plastics material at insulation notch place is difficult for the injection moulding combination when carrying out injection moulding for the second time, infiltration easily, and the injection moulding effect is relatively poor.
Summary of the invention
The present invention provides a kind of stator module, dc brushless motor and manufacturing approach thereof and draining pump, so that the injection structure of stator module is integrated, reduces the slit, thereby avoids taking place phenomenon of osmosis.
The embodiment of the invention provides a kind of manufacturing approach of stator module, comprising:
Stator core is carried out the injection moulding first time, and the end face edge place of the formed injection molding body of injection moulding for the first time is formed with weld bond;
Coiling on said injection molding body;
To carry out injection moulding second time, said injected plastics material fuses said weld bond, and solidifies the formation stator module with the weld bond material mixing after fusing to the injected plastics material of the injection molding body cast molten condition that is wound with coil.
The embodiment of the invention also provides a kind of stator module, wherein, adopts the manufacturing approach manufacturing of stator module provided by the present invention to form.
The embodiment of the invention also provides a kind of manufacturing approach of dc brushless motor; Wherein, comprise the manufacturing approach of stator module provided by the present invention, and after forming stator module; Also comprise: assemble rotor parts, motor shaft and end cap on stator module, to form dc brushless motor.
The embodiment of the invention also provides a kind of dc brushless motor; Comprise rotor part, motor shaft, upper end cover and bottom end cover; Wherein: also comprise stator module provided by the present invention; Said stator module and rotor part are arranged in the cavity of said upper end cover and bottom end cover formation; Said motor shaft is located in said upper end cover and the bottom end cover, and said rotor part is set in the said motor shaft outside.
The embodiment of the invention also provides a kind of draining pump, comprises the pump housing and motor, and wherein: said motor adopts dc brushless motor provided by the present invention.
Stator module provided by the invention, dc brushless motor and manufacturing approach thereof and draining pump; Form weld bond during through first time injection moulding; Can fuse weld bond with injected plastics material when making injection moulding for the second time; Then the boundary of twice injection moulding obtains good sealing-in through the fusion of weld bond; Reduce the possibility that the slit occurs, thereby avoided taking place phenomenon of osmosis.
Description of drawings
Fig. 1 is the structural representation of existing dc brushless motor;
Fig. 2 is the structural representation of stator punching in the existing stator module;
Fig. 3 is the structural representation of stator core in the existing stator module;
The flow chart of the manufacturing approach of the stator module that Fig. 4 provides for the embodiment of the invention;
Fig. 5 is the structural representation of injection molding body in the embodiment of the invention;
Fig. 6 is the structural representation of the injection molding body of coiling in the embodiment of the invention;
Fig. 7 is the structural representation of the stator module of embodiment of the invention manufacturing;
Fig. 8 is the side-looking cross-sectional view of injection molding body in the embodiment of the invention;
Fig. 9 is the local structure for amplifying sketch map at injection molding body notch place in the embodiment of the invention;
The manufacturing approach flow chart of the stator module that Figure 10 provides for another embodiment of the present invention;
The structural representation of the draining pump that Figure 11 provides for the embodiment of the invention.
Reference numeral:
The 100-motor; The 101-motor shaft; The 102-upper end cover;
The 103-bottom end cover; The 104-stator module; The 105-rotor field spider;
The 106-rotor magnetic steel; The 107-circuit board; The 108-stator tooth;
The 109-stator slot; The 110-notch; The 111-axis hole;
The 112-weld bond; The 113-injection molding body; The 114-coil;
The 115-fluting; The 116-positioning table; The 117-contact pin;
The 200-pump housing; The 201-upper pump casing; The 202-lower pump body;
The 203-impeller; The 301-drip tray; The 302-water inlet;
The 303-delivery port; The 304-outlet pipe.
Embodiment
For the purpose, technical scheme and the advantage that make the embodiment of the invention clearer; To combine the accompanying drawing in the embodiment of the invention below; Technical scheme in the embodiment of the invention is carried out clear, intactly description; Obviously; Described embodiment is the present invention's part embodiment, rather than whole embodiment.Based on the embodiment among the present invention, those of ordinary skills are not making the every other embodiment that is obtained under the creative work prerequisite, all belong to the scope of the present invention's protection.
The flow chart of the manufacturing approach of the stator module that Fig. 4 provides for the embodiment of the invention, this method comprises the steps:
Step 410, stator core is carried out the injection moulding first time; The end face edge place of the formed injection molding body 113 of injection moulding for the first time is formed with weld bond 112; Stator core normally is overrided to form by stator punching; Carry out integral molded plastic after forming stator core; Selected injected plastics material can be PA6 (nylon 6) or PP (polypropylene) etc., and the injection molding body 113 that injection moulding forms can be described as stator insulation;
Shown in Figure 5 is the structural representation of injection molding body in the embodiment of the invention; As shown in Figure 5; Weld bond 112 is formed on the edge of injection molding body 113 end faces; And it is concrete; Weld bond 112 preferably is formed on the outer circular edge and the internal circle edge of injection molding body 113 end faces; Can form continuous annulus boss in outer circular edge, can be the interrupted boss with the end surface shape coupling at internal circle edge place.The injection molding body 113 that has weld bond 112 structures can be constructed weld bond 112 through selecting suitably mould.Weld bond 112 both can be the boss that protrudes in end face, also can be to form groove in end face edge the edge of groove and as weld bond 112.
Step 420, on injection molding body 113 coiling 114, promptly form stator winding, weld bond 112 optimum seeking sites of aforementioned formation be to contain all coils 114;
Shown in Figure 6 is the structural representation of the injection molding body of coiling in the embodiment of the invention, and as shown in Figure 6, this injection molding body 113 has formed six stator tooths and stator slot 109, then correspondingly is wound with six stator coils 114.
Step 430, to the injected plastics material of the injection molding body that is wound with coil 114 113 cast molten conditions to carry out the injection moulding second time; Injected plastics material fuses weld bond 112 whole or in part; And with the fusion after weld bond 112 material mixing solidify the formation stator module, as shown in Figure 7.
Step 440, circuit board is soldered on the lead-in wire of coil 114 in the stator module and fixes.
Circuit board can be formed in the stator module part as stator module; Also can shown in present embodiment, be welded on the stator module, then when assembling motor; End cap etc. is located in outside the stator module, carry out embedding with epoxy resin and encapsulate fixing circuit board and stator module.
In the present embodiment; In the process of carrying out injection moulding for the second time; If as prior art; The end face of injection molding body is smooth; Then secondary fusion injected plastics material is difficult to the whole end face of injection molding body is heated to fusion; So tend to make the material of twice injection moulding to solidify independently, form the slit at boundary.And the technical scheme of employing present embodiment; Weld bond is the structure that protrudes in the injection molding body end face; Secondary fusion injected plastics material can surround with the top from the side of weld bond and contact weld bond; It is heated; Because the volume of weld bond is less relatively, is easy to make the weld bond fusion and mixes with secondary injected plastics material and to solidify.
Therefore, adopt the technical scheme of present embodiment, make the boundary of twice injection moulding can be good at combining, reduce the possibility that the slit occurs.When weld bond sealing when being formed on outer circular edge and the internal circle edge place of end face; Then make the winding coil of stator module can be completely enclosed within the material of injection moulding for the second time; Improved the sealing of winding coil, avoided taking place phenomenon of osmosis, avoided winding coil to make moist and cause defective insulation.Simultaneously, hermetically-sealed construction can make coil directly carry out heat conduction and heat radiation through injected plastics material, can increase the heat-sinking capability of coil, reduces temperature rise, improves performance.
Shown in Figure 8 is the side-looking cross-sectional view of injection molding body in the embodiment of the invention; As shown in Figure 8; Weld bond 112 is formed on the upper surface and the place, lower surface of injection molding body 113; Be parallel on the direction of stator module axis; The cross sectional shape of weld bond 112 is a triangle, and leg-of-mutton tip deviates from stator core.Usually, the weld bond cross section that the outer circular edge place can be set is the triangle of base 1 ± 0.3mm, height 1 ± 0.3mm.The weld bond at corresponding internal circle edge place, stator tooth place is the triangle of base 1 ± 0.3mm, height 1 ± 0.3mm, so that fusion mixes.
This technical scheme can have the mould of setting drafting angle through employing and stator core is carried out the injection moulding first time realize; The end face edge place of the formed injection molding body of injection moulding for the first time is formed with weld bond; This weld bond angle of section is by setting the drafting angle decision; The span of setting drafting angle is 20 °~40 °, and promptly formed weld bond cross section angle is 20 °~40 °.Formation has most advanced and sophisticated weld bond, is beneficial to the intensification fusion of weld bond more.
In the present embodiment; When stator core is carried out first time injection moulding; Can also be simultaneously on injection molding body 113 notch 110 places of stator slot 109 be formed with fluting 115; Be illustrated in figure 9 as the local structure for amplifying sketch map at injection molding body notch place in the embodiment of the invention; Fluting 115 is parallel with the axis of stator module; Vertically be opened in the edge of notch 110 sidewall adjacent stator grooves 109, can offer continuously also and can offer several sections intermittently.With the function class of weld bond 112 seemingly, form after the fluting 115, the edge of fluting 115 is the less relatively edge line in cross section, is easier to fusion under the heating of melted material, fuses with melted material and solidifies.The cross sectional shape of fluting 115 is preferably triangle, and leg-of-mutton tip deviates from notch 110.
On the basis of technique scheme, in step 410, preferably the edge at injection molding body 113 forms positioning table 116; As shown in Figure 6; So that when carrying out second time injection moulding, can combine positioning table 116 to position again through the inside and outside circle of injection molding body 113, as the both ends of the surface of locating surface.
On the basis of technique scheme; Step 420 specifically can comprise in the step of coiling 114 on the injection molding body 113: contact pin 117 is set on injection molding body 113; As shown in Figure 6, and the head and the tail of coil 114 are wound on the contact pin 117, contact pin 117 is equivalent to the lead-in wire of coil 114.Make like this contact pin 117 to go between and draw from the fixed position that circuit board can be directly with contact pin 117 welding, contact pin 117 plays the fixing circuit board effect simultaneously.
The manufacturing approach flow chart of the stator module that Figure 10 provides for another embodiment of the present invention, the method for present embodiment comprises the steps:
Step 10, stator core is carried out the injection moulding first time, the end face edge place of the formed injection molding body of injection moulding for the first time is formed with weld bond;
Step 20, contact pin is set on injection molding body, the head and the tail of coil are wound on the contact pin;
Step 30, circuit board is positioned on the contact pin; And it is fixing with the contact pin welding; The mode of contact pin locating circuit board can be that pin hole is set on circuit board; The mode of inserting pin hole with many contact pins respectively positions, and positions as long as the layout that electric component on the circuit board rationally is set can leave the pin hole position;
Step 40, to the injected plastics material of the injection molding body cast molten condition that is welded with circuit board to carry out injection moulding second time, injected plastics material fuses weld bond, and solidifies the formation stator module with the weld bond material mixing after fusing.
In the present embodiment, for the first time structure such as the formed weld bond of injection moulding can be referring to previous embodiment, is with the difference of previous embodiment: carrying out injection moulding second time soldered circuit board before.In the aforementioned embodiment, because circuit board just welding after the injection moulding second time so can adopt conventional injection molding technology, need not to consider the damage problem of injection moulding for the second time to circuit board.And in the present embodiment, can adopt existing low-voltage technology to carry out the injection moulding second time, in order to avoid injection moulding damages circuit board, the advantage of present embodiment is to fix with the encapsulation of injection moulding completion second time circuit board, can remove the technology of follow-up epoxy encapsulation from.
The embodiment of the invention also provides a kind of stator module, adopts the manufacturing approach manufacturing of the stator module that any embodiment of the present invention provided to form.The coil insulation performance of this stator module improves, thermal diffusivity is better, and easy to assembly, high conformity.
The embodiment of the invention also provides a kind of manufacturing approach of dc brushless motor; The manufacturing approach that comprises the stator module that any embodiment of the present invention provides; And after forming stator module; Also comprise: assemble rotor parts, motor shaft and end cap on the stator module of connecting circuit plate, to form dc brushless motor.
For the technology that is provided with of circuit board, can before or after the injection moulding for the second time the wire bonds of circuit board and coil be fixed carrying out, specifically can be that the employing contact pin positions and welds.
After carrying out injection moulding for the second time, the wire bonds of circuit board and coil fixedly the time, then after assemble rotor parts, motor shaft and end cap, is also carried out the epoxy resin embedding, with dimensional packaged circuit board.
The insulating motor coil performance of the manufacturing approach manufacturing of the dc brushless motor that the embodiment of the invention provided improves, thermal diffusivity is better; And it is easy to assembly; High conformity; Be particularly useful for the equipment that draining pump etc. is used in the heavy environment of high humidity, steam, can effectively prevent the invasion and attack of steam motor coil.
The embodiment of the invention also provides a kind of dc brushless motor; Comprise rotor part, motor shaft, upper end cover and bottom end cover; Wherein: the stator module that also comprises any embodiment of the present invention and provided; Stator module and rotor part are arranged in the cavity of upper end cover and bottom end cover formation; Motor shaft is located in upper end cover and the bottom end cover, and rotor part is set in the motor shaft outside.A kind of typical structure of dc brushless motor can be referring to shown in Figure 1.
The embodiment of the invention also provides a kind of draining pump, comprises the pump housing and motor, and this motor adopts the dc brushless motor that any embodiment of the present invention provided.The draining pump structure as shown in figure 11; With the employed draining pump of air conditioner is example; Draining pump is arranged in the drip tray 301; Comprise the dc brushless motor 100 and the pump housing 200; The pump housing 200 comprises upper pump casing 201 and lower pump body 202; Impeller 203 is in the inner chamber of upper pump casing 201 and lower pump body 202 containings; Hole and impeller 203 that the motor shaft 101 of motor 100 passes upper pump casing 201 are fixedly linked; 203 rotations of motor shaft 101 rotation impeller; Water in the drip tray 301 is directed to delivery port 303 from water inlet 302, then discharges from outlet pipe 304.Require this draining pump to have the lift of H1, to satisfy the requirement of draining.
The stator module that forms through the manufacturing approach manufacturing of stator module provided by the present invention; And dc brushless motor that assembles and draining pump; Can pass through weld bond; Particularly be formed on the weld bond and the notching construction at outer circular edge and internal circle edge place; Form airtight boss circumference, contain coil windings fully.Weld bond fusing after the injection moulding for the second time is integrally formed with the material of the injection moulding second time, reaches the effect of encapsulated coil.And then the assurance air humidity is than the insulation property of high ambient lower coil.Simultaneously, because the injected plastics material heat conductivility is better than air under the closed environment, injected plastics material and stator core are fitted, and stator core cooperates with end cap again, has improved the thermal diffusivity of coil, and this technical scheme is particularly useful for being operated in the draining electric motor for pump under the wet environment.
What should illustrate at last is: above embodiment is only in order to illustrating technical scheme of the present invention, but not to its restriction; Although with reference to previous embodiment the present invention has been carried out detailed explanation, those of ordinary skill in the art is to be understood that: it still can be made amendment to the technical scheme that aforementioned each embodiment put down in writing, and perhaps part technical characterictic wherein is equal to replacement; And these are revised or replacement, do not make the spirit and scope of the essence disengaging various embodiments of the present invention technical scheme of relevant art scheme.