Summary of the invention
The invention provides a kind of stator module, dc brushless motor and manufacture method thereof and draining pump, so that the injection structure of stator module is integrated, reduces the slit, thereby avoid taking place phenomenon of osmosis.
The embodiment of the invention provides a kind of manufacture method 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 described injection molding body;
To carry out injection moulding second time, described injected plastics material fuses described weld bond to the injected plastics material of the injection molding body cast molten condition that is wound with coil, and mixes and solidify the formation stator module with weld bond material after fusing.
The embodiment of the invention also provides a kind of stator module, wherein, adopts the manufacture method manufacturing of stator module provided by the present invention to form.
The embodiment of the invention also provides a kind of manufacture method of dc brushless motor, wherein, comprise the manufacture method 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, described stator module and rotor part are arranged in the cavity of described upper end cover and bottom end cover formation, described motor shaft is located in described upper end cover and the bottom end cover, and described rotor part is set in the described motor shaft outside.
The embodiment of the invention also provides a kind of draining pump, comprises the pump housing and motor, and wherein: described motor adopts dc brushless motor provided by the present invention.
Stator module provided by the invention, dc brushless motor and manufacture method thereof and draining pump, form weld bond during by 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 by the fusion of weld bond, reduce the possibility that the slit occurs, thereby avoided taking place phenomenon of osmosis.
Embodiment
For the purpose, technical scheme and the advantage that make the embodiment of the invention clearer, below in conjunction with the accompanying drawing in the embodiment of the invention, technical scheme in the embodiment of the invention is clearly and completely described, 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 belong to the scope of protection of the invention not making the every other embodiment that obtains under the creative work prerequisite.
The flow chart of the manufacture method 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;
Figure 5 shows that 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 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 by selecting suitably mould.Weld bond 112 both can be the boss that protrudes from 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, namely form stator winding, all coils 114 preferably can be contained in weld bond 112 positions of aforementioned formation;
Figure 6 shows that the structural representation of the injection molding body of coiling in the embodiment of the invention, 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 113 cast molten conditions that are wound with coil 114 to carry out the injection moulding second time, injected plastics material fuses weld bond 112 whole or in part, and mix and solidify the formation stator module with weld bond 112 materials after the fusion, 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 be welded on the stator module as shown in this embodiment, 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 from 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 combination, reduce the possibility that the slit occurs.When weld bond sealing when being formed on the outer circular edge of end face and internal circle edge place, 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 by injected plastics material, can increase the heat-sinking capability of coil, reduces temperature rise, improves performance.
Figure 8 shows that 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 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 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 by 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 determines by setting drafting angle, the span of setting drafting angle is 20 °~40 °, and namely 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 schematic diagram 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 fuse under the heating of melted material, solidifies with the melted material fusion.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 position in conjunction with positioning table 116 again by 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, the step of step 420 coiling 114 on injection molding body 113 specifically can comprise: at injection molding body 113 contact pin 117 is set, 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 manufacture method 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, at injection molding body contact pin is set, 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 at circuit board pin hole to be set, 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 mixes and solidify the formation stator module with weld bond material 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: soldered circuit board before carrying out the injection moulding second time.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 that injection moulding for the second time is to the damage problem of 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 that circuit board is finished in the injection moulding second time, can remove the technology of follow-up epoxy encapsulation from.
The embodiment of the invention also provides a kind of stator module, adopts the manufacture method manufacturing of the stator module that any embodiment of the present invention provides 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 manufacture method of dc brushless motor, the manufacture method 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 arranges 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 manufacture method manufacturing of the dc brushless motor that the embodiment of the invention provides 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 prevent effectively that steam is to the invasion and attack of 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: also comprise the stator module that any embodiment of the present invention provides, 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, the dc brushless motor that this motor adopts any embodiment of the present invention to provide.The draining pump structure as shown in figure 11, be example with the employed draining pump of air conditioner, draining pump is arranged in the drip tray 301, comprise 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 manufacture method manufacturing of stator module provided by the present invention, and the dc brushless motor that assembles and draining pump, can pass through weld bond, particularly be formed on 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, the material formation one with the injection moulding second time reaches the effect of encapsulated coil.And then the insulation property of the higher environment lower coil of assurance air humidity.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.
It should be noted that at last: above embodiment only in order to technical scheme of the present invention to be described, is not intended to limit; Although with reference to previous embodiment the present invention is had been described in detail, 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 puts down in writing, and perhaps part technical characterictic wherein is equal to replacement; And these modifications or replacement do not make the essence of appropriate technical solution break away from the spirit and scope of various embodiments of the present invention technical scheme.