WO2020042761A1 - 电子水泵及其机壳组件 - Google Patents

电子水泵及其机壳组件 Download PDF

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Publication number
WO2020042761A1
WO2020042761A1 PCT/CN2019/094988 CN2019094988W WO2020042761A1 WO 2020042761 A1 WO2020042761 A1 WO 2020042761A1 CN 2019094988 W CN2019094988 W CN 2019094988W WO 2020042761 A1 WO2020042761 A1 WO 2020042761A1
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WO
WIPO (PCT)
Prior art keywords
casing
stator
assembly
injection molded
impeller
Prior art date
Application number
PCT/CN2019/094988
Other languages
English (en)
French (fr)
Inventor
王东
葛笑
陈华江
Original Assignee
广东威灵汽车部件有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from CN201821424766.2U external-priority patent/CN208749589U/zh
Priority claimed from CN201811014637.0A external-priority patent/CN110873062A/zh
Application filed by 广东威灵汽车部件有限公司 filed Critical 广东威灵汽车部件有限公司
Priority to EP19853681.5A priority Critical patent/EP3800355A4/en
Priority to JP2021518843A priority patent/JP7118257B2/ja
Publication of WO2020042761A1 publication Critical patent/WO2020042761A1/zh
Priority to US17/119,173 priority patent/US12078191B2/en

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/60—Mounting; Assembling; Disassembling
    • F04D29/605—Mounting; Assembling; Disassembling specially adapted for liquid pumps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/40—Casings; Connections of working fluid
    • F04D29/42—Casings; Connections of working fluid for radial or helico-centrifugal pumps
    • F04D29/426—Casings; Connections of working fluid for radial or helico-centrifugal pumps especially adapted for liquid pumps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D13/00—Pumping installations or systems
    • F04D13/02—Units comprising pumps and their driving means
    • F04D13/06—Units comprising pumps and their driving means the pump being electrically driven
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/02—Selection of particular materials
    • F04D29/026—Selection of particular materials especially adapted for liquid pumps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/40—Casings; Connections of working fluid
    • F04D29/406—Casings; Connections of working fluid especially adapted for liquid pumps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/20—Manufacture essentially without removing material

Definitions

  • the present application relates to the technical field of electronic water pumps, and in particular, to a casing component of an electronic water pump and an electronic water pump including the casing component.
  • a related art discloses a motor structure of an electronic water pump.
  • a stator assembly includes a mandrel, an armature, a rear thrust pad, and a stator injection layer.
  • the armature, a mandrel, and a rear thrust pad are injection-molded into one body.
  • the injection molding layer of the stator is a BMC thermosetting molding compound block, which has the following disadvantages: 1)
  • the injection molding layer of the stator is a BMC thermosetting molding compound block, which has low strength and cannot meet the strength of the motor casing.
  • This application aims to solve at least one of the above technical problems.
  • an object of the first aspect of the present application is to provide a casing assembly of an electronic water pump.
  • An object of the second aspect of the present application is to provide an electronic water pump including the casing assembly.
  • the casing component includes a stator component and an injection molded body of the casing.
  • the stator component is integrally injection-molded. It is made by secondary injection molding, and the stator assembly is wrapped inside the casing injection molding body to form a self-sealing.
  • the technical solution of the present application further provides a casing assembly of the electronic water pump.
  • the casing assembly includes a stator assembly, a rotating shaft, a shaft base, and an injection molded body of the casing.
  • the stator assembly is integrally injection-molded.
  • the casing component is injection molded twice, the rotating shaft and the shaft base are both embedded inside the casing injection molded body, and the stator component is wrapped inside the casing injection molded body to form a self-sealing.
  • the casing component of the electronic water pump provided by any of the above technical solutions of the present application is integrally injection-molded of the stator component, and then the stator component and the casing injection-molded body (that is, the casing of the motor) are injection-molded twice to realize self-sealing with the rotor. Function, eliminating the need for the insulation sleeve between the stator and rotor air gap, reducing the material cost of the casing, simplifying the assembly process of the electronic water pump, and increasing the stiffness of the stator assembly, which is conducive to the improvement of the noise of the electronic water pump and improves the electronic water pump. Reliable operation. Therefore, the casing components of the electronic water pump of the above solution have obvious advantages in terms of installation process, cost, and performance.
  • stator assembly is integrally injection-molded first, and then the casing assembly is injection-molded again.
  • the injection-molded stator body of the injection-molded stator assembly can be injection-molded at a lower cost than the casing injection-molded body.
  • the above solution saves material costs; again, the stator injection molding body and the casing injection molding body are separately injection molded, so that the stator injection molding body has a smaller volume and the injection molding time is shorter, and the stator injection molding body does not face the stator. Parts such as windings inside the injection molding body are damaged, thereby ensuring the reliability of the performance of the electronic water pump.
  • casing assembly of the electronic water pump provided in the above technical solution of the present application may also have the following additional technical features:
  • the stator assembly includes a pin, a winding, an insulating frame, a stator core, and a stator injection molded body, the insulating frame surrounds the stator core, and the winding is wound around the insulating frame
  • the pin is fixed in a groove of the insulating frame, and the stator injection molding body wraps and fastens the pin, the winding, the insulating frame, and the stator core.
  • the stator injection molding body is used to wrap and fasten the entire component of the stator assembly, thereby injection molding the stator assembly as a whole.
  • the stator assembly includes a stator injection molded body, and the stator injection molded body is a thermosetting material, and the solid deformation temperature of the thermosetting material is not lower than the injection temperature of the casing injection molded body.
  • the stator injection molding body is made of thermosetting material, preferably BMC thermosetting material, and the material cost is low; the solid deformation temperature of the thermosetting material is not lower than the injection temperature of the casing injection molding body, so as to avoid melting the injection molding stator when the casing components are re-injected Risk of injection molding.
  • the stator assembly includes a stator injection molded body, the stator injection molded body is a thermosetting material, and the casing injection molded body is a PPS material.
  • the stator injection molding body uses a lower cost thermosetting material, preferably a BMC thermosetting material, and the casing injection molding body uses a higher strength PPS material, which not only ensures the strength of the casing injection molding body, but also saves material costs.
  • the stator assembly includes a stator injection molded body, and a material strength of the housing injection molded body is greater than a material strength of the stator injection molded body.
  • the stator assembly is integrally injection-molded first, and then the casing assembly is injection-molded again.
  • the stator injection-molded body of the injection-molded stator assembly and the casing injection-molded body of the injection-molded casing assembly can use different injection molding materials, and the strength required by the casing injection-molded body High, can use higher cost injection molding, and the stator injection molded body requires low strength, can use lower cost injection molding, compared with the stator injection molding layer in the related art as the motor housing, the above scheme not only guarantees the machine The strength of the shell injection molding saves material costs.
  • the technical solution of the second aspect of the present application provides an electronic water pump including a hydraulic part, a brushless motor part, and a control part.
  • the hydraulic part includes a pump casing and an impeller; the brushless motor part includes a rotor and any one of the above.
  • the electronic water pump provided by the above technical solution of the present application because it includes the casing component of any of the foregoing technical solutions, has the beneficial effects of the casing component of any of the above technical solutions.
  • the impeller and the rotor are integrally injection molded into an impeller rotor assembly.
  • the impeller of the hydraulic part and the rotor of the brushless motor part are integrally injection-molded, and are respectively installed inside the pump casing and the casing, so that the manufacturing of the impeller rotor assembly is convenient and the cost is low.
  • the impeller includes an impeller body and a blade
  • the rotor includes a rotor core, a magnetic steel, and a shaft sleeve
  • the rotor core is provided with a magnetic steel slot
  • the magnetic steel is mounted on the In the magnetic steel groove
  • the rotor core and the magnetic steel are plastic-sealed inside the impeller body to become an impeller rotor assembly one
  • the sleeve is overmolded into the impeller rotor assembly one to become the impeller rotor assembly two.
  • the second impeller rotor assembly is connected to the blade to form the impeller rotor assembly.
  • the impeller rotor assembly of the above solution includes an impeller and a rotor.
  • the impeller includes an impeller body and a blade.
  • the rotor includes an iron core, a magnetic steel, and a shaft sleeve.
  • the impeller rotor assembly is formed by a two-step injection molding process.
  • the second step is injection molding the sleeve, so that the impeller body can be made of a material that is cheaper than the sleeve, which saves manufacturing costs compared to the impeller rotor assembly that is integrally molded with the sleeve and the impeller body.
  • the iron core and magnetic steel are plastically sealed. In the impeller body, the bonding is firm; the sleeve is small in size and light in weight.
  • the blade is an injection molded body, and the impeller rotor assembly 2 and the blade are integrated by ultrasonic welding.
  • the impeller is formed by ultrasonic welding process, and the blade and the rotor assembly are integrated by ultrasonic welding.
  • the injection mold with integrated impeller injection molding has a complicated structure and high maintenance costs. Therefore, the impeller is divided into two parts: the impeller body and the blade. With ultrasonic welding for molding, the structure of the injection mold is simple, which greatly reduces the maintenance cost of the injection mold.
  • the abrasion resistance of the shaft sleeve is better than that of the impeller body.
  • the impeller rotor assembly is formed by a two-step injection molding process.
  • the first step is injection molding the impeller body and the second step is injection molding the bushing.
  • the material requirements for the injection impeller body are: High strength, acid and alkali resistance
  • the material requirements of the injection bushing are wear resistance
  • the material cost of the injection bushing is high
  • the material cost of the injection impeller body is low, compared to the shaft sleeve and the impeller body
  • the integrally molded impeller rotor assembly saves manufacturing costs.
  • a first seal ring is installed between the front end of the casing injection molded body of the casing assembly and the pump casing to form a closed hydraulic cavity; the casing assembly A second sealing ring is installed between the rear end of the injection molded body of the casing and the rear end cover to form a closed electrical control cavity.
  • the control board of the control part is installed in the electric control cavity enclosed by the casing and the rear cover.
  • the brushless motor part is installed between the water conservancy part and the control part.
  • the stator assembly of the brushless motor part is integrally injection-molded. And it is injection-molded with the casing; a seal ring is installed between the casing of the brushless motor section and the pump casing, and between the casing of the brushless motor section and the rear end cover, so as to realize the sealing of the electronic water pump.
  • the hydraulic portion and the brushless motor portion are fixedly connected by screws, and the brushless motor portion and the control portion are fixedly connected by screws, which facilitates assembly and secure connection.
  • FIG. 1 is a schematic sectional structural view of a stator assembly according to an embodiment of the present application
  • FIG. 2 is a schematic cross-sectional structural diagram of a casing component according to an embodiment of the present application
  • FIG. 3 is a schematic cross-sectional structure diagram of an electronic water pump according to an embodiment of the present application.
  • FIG. 4 is a schematic sectional structural view of an impeller rotor assembly according to an embodiment of the present application.
  • a casing assembly 1 of an electronic water pump includes a stator assembly 11, a rotating shaft 12, a shaft base 13 and a casing injection-molded body 14, and the stator assembly 11 is integral. It is injection-molded, and the casing component 1 is over-molded.
  • the shaft 12 and the shaft base 13 are in an interference fit. Both the shaft 12 and the shaft base 13 are embedded in the injection-molded body 14 of the casing.
  • the stator assembly 11 is wrapped inside the injection-molded body 14 of the casing. Forms a self-sealing.
  • the casing assembly 1 of the electronic water pump provided in the above embodiments of the present application is integrally injection-molded of the stator assembly 11, and then the stator assembly 11 and the casing are second injection-molded to achieve self-sealing with the rotor, eliminating the need for fixed rotor air.
  • the gap between the gaps reduces the material cost of the casing, simplifies the assembly process of the electronic water pump, and improves the rigidity of the stator assembly 11, which is beneficial to the improvement of the noise of the electronic water pump and the reliability of the operation of the electronic water pump.
  • the housing assembly 1 of the proposed electronic water pump has obvious advantages in terms of installation process, cost and performance.
  • stator assembly 11 is integrally injection-molded first, and the casing assembly 1 is injection-molded again, so that the injection molded body 114 of the stator of the injection-molded stator assembly 11 and the casing injection-molded body 14 of the injection-molded casing assembly 1 can use different injection-molded plastics, and the casing
  • the injection molded body 14 requires high strength and can use higher cost injection molding, while the stator injection molded body 114 requires low strength and can use lower cost injection molding.
  • the stator injection molding layer is used as the motor casing.
  • stator injection molding body 114 and the casing injection molding body 14 are separately injection molded, so that the volume of the stator injection molding body 114 is small and the injection molding time is small. Shorter, the injection molding of the stator injection mold body 114 will not cause damage to the winding 112 and other components inside the stator injection mold body 114, thereby ensuring the performance reliability of the electronic water pump.
  • the stator assembly 11 includes a pin 111, a winding 112, an insulating frame 115, a stator core 113, and a stator injection molded body 114.
  • the insulating frame 115 surrounds the stator core 113, and the winding 112 is wound around the teeth of the insulating frame 115, and the pin 111 is fixed in the groove of the insulating frame 115.
  • the injection molded body 114 of the stator encapsulates the pin 111, the winding 112, the insulating frame 115, and the stator core 113, and the stator is injection-molded.
  • the body 114 wraps and fastens the entire components of the stator assembly 11, so that the stator assembly 11 is injection-molded as a whole.
  • the stator assembly 11 includes a stator injection molding body 114, which is a thermosetting material, and the solid deformation temperature of the thermosetting material is not lower than the injection temperature of the casing injection molding body 14.
  • the stator injection molding body 114 is made of thermosetting material, preferably BMC thermosetting material, and the material cost is low; the solid deformation temperature of the thermosetting material is not lower than the injection temperature of the casing injection molding body 14 to avoid melting and injection molding once during the secondary injection molding of the casing component 1 The risk of a molded stator body 114.
  • the stator assembly 11 includes a stator injection molded body 114, the stator injection molded body 114 is a thermosetting material, and the casing injection molded body 14 is a PPS material.
  • the stator injection molding body 114 uses a lower cost thermosetting material, preferably a BMC thermosetting material, and the casing injection molding body 14 uses a higher strength PPS material, which not only ensures the strength of the casing injection molding body 14 but also saves material costs.
  • an embodiment of the second aspect of the present application provides an electronic water pump including a hydraulic part, a brushless motor part, and a control part.
  • the hydraulic part includes a pump casing 2 and an impeller;
  • the brushless motor part includes a rotor and a
  • the control section includes a control board 6 and a rear cover 7; the brushless motor section is installed between the hydraulic section and the control section.
  • the electronic water pump provided by the foregoing embodiments of the present application has the beneficial effects of the casing assembly 1 of any of the foregoing embodiments because it includes the casing assembly 1 of any of the foregoing embodiments, and details are not described herein again.
  • the impeller and the rotor are integrally injection molded into the impeller rotor assembly 3.
  • the impeller of the hydraulic part and the rotor of the brushless motor part are integrally injection-molded, and are respectively installed inside the pump casing 2 and the casing, so that the manufacturing of the impeller rotor assembly 3 is convenient and the cost is low.
  • the impeller includes an impeller body 34 and a blade 35
  • the rotor includes a rotor core 33, a magnetic steel 32, and a shaft sleeve 31, and the rotor core 33 is provided with a magnetic steel 32 slot.
  • the magnetic steel 32 is installed in the magnetic steel 32 slot, the rotor core 33 and the magnetic steel 32 are plastically sealed inside the impeller main body 34 to become the impeller rotor assembly 1, and the bushing 31 is injection molded into the impeller rotor assembly 1 to become the impeller rotor assembly 2.
  • the second impeller rotor assembly is connected to the blade 35 to form the impeller rotor assembly 3.
  • the impeller rotor assembly 3 of the above solution includes an impeller and a rotor.
  • the impeller includes an impeller body 34 and a blade 35.
  • the rotor includes a rotor core 33, a magnetic steel 32, and a sleeve 31.
  • the impeller rotor assembly 3 is formed by a two-step injection molding process. In the first step, the impeller body 34 is injection-molded, and in the second step, the shaft sleeve 31 is injection-molded. In this way, the injection material used for the injection molding of the impeller body 34 and the sleeve 31 may be different. Alkali, the material requirements of the injection sleeve 31 are wear-resistant, high strength, acid and alkali resistance.
  • the material cost of the injection sleeve 31 is high, and the material cost of the injection impeller body 34 is low, compared with the sleeve 31 and the impeller body 34.
  • the integrally molded impeller rotor assembly 3 saves manufacturing costs; secondly, the iron core and magnetic steel 32 are plastically sealed in the impeller main body 34, which is firmly bonded; the shaft sleeve 31 is small in size and light in weight.
  • the impeller rotor assembly 3 When the impeller rotor assembly 3 rotates, it drives The rotating torque of the shaft sleeve 31 is small, and the shaft sleeve 31 is not easy to slip; again, the impeller body 34 is large, the shaft sleeve 31 is small, and the speed of the injection shaft sleeve 31 is fast, which will not affect the impeller rotor assembly. , I.e. it does not melt during the second injection molding of the sleeve 31 the first injection molded impeller main body, thus avoiding the well core and the magnet 32 shift risk.
  • the blade 35 is an injection molded body, and the impeller rotor assembly 2 and the blade 35 are integrated by ultrasonic welding to become the impeller rotor assembly 3.
  • the impeller is formed by ultrasonic welding process, and the blade 35 and the impeller rotor assembly are welded into one by ultrasonic welding.
  • the injection mold with integrated impeller injection molding has a complicated structure and high maintenance costs. Therefore, the impeller is divided into two parts: the impeller main body 34 and the blade 35. For molding, a welding line is provided on the blade 35, a welding groove is provided on the impeller body 34, and then ultrasonic welding is used for molding.
  • the structure of the injection mold is simple, and the maintenance cost of the injection mold is greatly reduced.
  • a first sealing ring 4 is installed between the front end of the casing injection body 14 of the casing assembly 1 and the pump casing 2 to form a closed hydraulic cavity; the rear end of the casing injection body 14 of the casing assembly 1
  • a second sealing ring 5 is installed between the rear end cover 7 to form a sealed electric control cavity.
  • the control board 6 of the control section is installed inside the electric control cavity surrounded by the casing and the rear cover 7.
  • the motor section realizes the current commutation by setting the control board 6 to ensure the continuous rotation of the motor;
  • the brushless motor section is installed Between the water conservancy department and the control department;
  • the stator assembly 11 of the brushless motor section is integrally injection-molded and is second injection-molded with the casing;
  • the casing of the brushless motor section and the pump casing 2 and the casing of the brushless motor section Sealing rings are respectively installed between the rear end cover 7 and the electronic water pump for sealing.
  • the hydraulic part and the brushless motor part are fixedly connected by screws, and the brushless motor part and the control part are fixedly connected by screws, which is convenient to assemble and is firmly connected.
  • the electronic water pump includes a hydraulic part, a brushless motor part, and a control part; the impeller of the hydraulic part and the rotor of the brushless motor part are integrally injection molded, and are respectively installed in the pump casing 2 And the inside of the case; the control board 6 of the control part is installed in the electric control cavity surrounded by the case and the rear cover 7; the brushless motor part is installed between the hydraulic part and the control part;
  • the stator assembly 11 is integrally injection-molded, and is second injection-molded with the casing; a seal ring is respectively installed between the casing of the brushless motor section and the pump casing 2, the casing of the brushless motor section and the rear end cover 7,
  • the sealing of the electronic water pump is realized; the above solution uses the integral injection molding technology of the stator and the casing not only saves the material cost of the traditional electronic water pump casing, but also eliminates the isolation sleeve in the middle of the air gap of the fixed rotor, and simplifies the installation of
  • the electronic water pump is an electronic water pump for a vehicle.
  • connection should be understood in a broad sense, unless explicitly stated and limited otherwise.
  • “connected” may be a fixed connection or it may be removable.
  • the specific meanings of the above terms in this application can be understood according to specific situations.

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  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
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Abstract

一种电子水泵及其机壳组件（1），电子水泵的机壳组件（1）包括：定子组件（11）、转轴（12）、轴底座（13）和机壳注塑体（14），定子组件（11）整体注塑而成，机壳组件（1）二次注塑而成，转轴（12）和轴底座（13）均嵌入机壳注塑体（14）内部，定子组件（11）包裹于机壳注塑体（14）内部形成自密封。

Description

电子水泵及其机壳组件
本申请要求于2018年08月31日提交中国专利局、申请号为201811014637.0、发明创造名称为“电子水泵及其机壳组件”和于2018年08月31日提交中国专利局、申请号为201821424766.2、发明创造名称为“电子水泵及其机壳组件”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本申请涉及电子水泵技术领域，具体而言，涉及一种电子水泵的机壳组件及一种包括该机壳组件的电子水泵。
背景技术
鉴于能源节俭的大环境，现代高端汽车和电动汽车大多用电子冷却水泵代替了原有的机械水泵，电子水泵相比传统水泵具有控制精确，效率更高的优势。传统电子水泵定子装于机壳，转子与叶轮在水力部，定子与转子之间具有隔离套，起密封作用，传统电子水泵零部件多，装配复杂，成本高。
相关技术中公开了一种电子水泵的电机结构，定子组件包括芯轴、电枢、后止推垫、定子注塑层，电枢、芯轴和后止推垫注塑成一体，定子注塑层具有电机壳体、端盖和定子隔离套的作用，定子注塑层为BMC热固性模塑料块，存在以下弊端：1)定子注塑层采用BMC热固性模塑料块，强度低，不能满足电机壳体的强度需求；2)定子注塑层的体积大，注塑成型的时间长，很容易对包裹于定子注塑层内部的绕组等造成损坏；3)若定子注塑层采用强度较高的PPS材料，会造成制造成本增加。
发明内容
本申请旨在解决上述技术问题至少之一。
为此，本申请第一方面的目的在于，提供一种电子水泵的机壳组件。
本申请第二方面的目的在于，提供一种包括上述机壳组件的电子水泵。
为了实现上述目的，本申请的技术方案提供了一种电子水泵的机壳组件，所述机壳组件包括定子组件和机壳注塑体，所述定子组件整体注塑而成，所述机壳组件二次注塑而成，所述定子组件包裹于所述机壳注塑体内部形成自密封。
为了实现上述目的，本申请的技术方案还提供了一种电子水泵的机壳组件，所述机壳组件包括定子组件、转轴、轴底座和机壳注塑体，所述定子组件整体注塑而成，所述机壳组件二次注塑而成，所述转轴和所述轴底座均嵌入所述机壳注塑体内部，所述定子组件包裹于所述机壳注塑体内部形成自密封。
本申请上述任一技术方案提供的电子水泵的机壳组件，将定子组件整体注塑而成，再将定子组件与机壳注塑体(即电机的机壳)二次注塑成型，与转子实现自密封作用，省去了定转子气隙间的隔离套，降低了机壳材料成本，同时简化了电子水泵的装配工艺，并使得定子组件的刚度提升，有利于电子水泵噪音的改善，提高了电子水泵运行的可靠性，因此上述方案的电子水泵的机壳组件，在安装工艺、成本以及性能上均具有明显的优势。
其次，先整体注塑成型定子组件，再二次注塑成型机壳组件，这样注塑定子组件的定子注塑体可以采用比机壳注塑体成本低的注塑料，相较于相关技术中定子注塑层作为电机壳体，上述方案节省了材料成本；再次，将定子注塑体和机壳注塑体分别注塑成型，使得定子注塑体的体积较小，注塑成型时间较短，注塑定子注塑体时不会对定子注塑体内部的绕组等部件造成损坏，从而确保电子水泵的性能可靠性。
另外，本申请上述技术方案中提供的电子水泵的机壳组件还可以具有如下附加技术特征：
在上述技术方案中，优选地，所述定子组件包括插针、绕组、绝缘框架、定子铁芯和定子注塑体，所述绝缘框架包裹所述定子铁芯，所述绕组缠绕于所述绝缘框架的齿部，所述插针固定于所述绝缘框架的凹槽内，所述定子注塑体将所述插针、所述绕组、所述绝缘框架和所述定子铁芯包裹紧固。
利用定子注塑体将定子组件的整个部件包裹紧固，从而将定子组件整体注 塑为一体。
在上述技术方案中，优选地，所述定子组件包括定子注塑体，所述定子注塑体为热固性材料，所述热固性材料的固性变形温度不低于所述机壳注塑体的注塑温度。
定子注塑体采用热固性材料，优选采用BMC热固性材料，材料成本低；热固性材料的固性变形温度不低于机壳注塑体的注塑温度，以避免二次注塑机壳组件时熔融一次注塑成型的定子注塑体的风险。
在上述技术方案中，优选地，所述定子组件包括定子注塑体，所述定子注塑体为热固性材料，所述机壳注塑体为PPS材料。
定子注塑体采用成本较低的热固性材料，优选采用BMC热固性材料，机壳注塑体采用强度较高的PPS材料，既保证机壳注塑体的强度，又节省了材料成本。
在上述技术方案中，优选地，所述定子组件包括定子注塑体，所述机壳注塑体的材料强度大于所述定子注塑体的材料强度。
上述方案，先整体注塑成型定子组件，再二次注塑成型机壳组件，这样注塑定子组件的定子注塑体和注塑机壳组件的机壳注塑体可以采用不同注塑料，机壳注塑体要求的强度高，可以采用成本较高的注塑料，而定子注塑体要求的强度低，可以采用成本较低的注塑料，相较于相关技术中定子注塑层作为电机壳体，上述方案既保证了机壳注塑体的强度，又节省了材料成本。
本申请第二方面的技术方案提供了一种电子水泵，包括水力部、无刷电机部及控制部，所述水力部包括泵壳及叶轮；所述无刷电机部包括转子和如上述任一技术方案所述的机壳组件；所述控制部包括控制板和后端盖；所述无刷电机部装设于所述水力部和所述控制部之间。
本申请上述技术方案提供的电子水泵，因其包括上述任一技术方案的机壳组件，因而具有上述任一技术方案的机壳组件的有益效果。
在上述技术方案中，优选地，所述叶轮和所述转子一体注塑而成成为叶轮转子组件。
水力部的叶轮与无刷电机部的转子一体注塑而成，分别装设于泵壳与机壳内部，使得叶轮转子组件的制造方便，成本低。
在上述技术方案中，优选地，所述叶轮包括叶轮主体和叶片，所述转子包括转子铁芯、磁钢和轴套，所述转子铁芯上设有磁钢槽，所述磁钢安装在所述磁钢槽内，所述转子铁芯和所述磁钢塑封在所述叶轮主体内部成为叶轮转子组件一，所述轴套二次注塑于所述叶轮转子组件一中成为叶轮转子组件二，所述叶轮转子组件二与所述叶片相连成为所述叶轮转子组件。
上述方案的叶轮转子组件，包括叶轮和转子两部分，叶轮包括叶轮主体、叶片；转子包括铁芯、磁钢、轴套，叶轮转子组件通过两步注塑工艺成型，第一步注塑成型叶轮主体，第二步注塑成型轴套，这样叶轮主体可以采用比轴套便宜的材料制成，相比于轴套与叶轮主体一体注塑的叶轮转子组件，节省了制造成本；其次，铁芯、磁钢塑封在叶轮主体内，粘接牢固；轴套体积小，重量轻，叶轮转子组件在旋转时，带动轴套旋转的扭矩小，轴套不易打滑；再次，叶轮主体体积大，轴套体积小，注塑轴套时速度快，不会对叶轮转子组件一造成影响，也即在二次注塑成型轴套时不会熔融第一次注塑成型的叶轮主体，因此很好地避免了铁芯和磁钢移位的风险。
在上述技术方案中，优选地，所述叶片为注塑体，所述叶轮转子组件二与所述叶片通过超声波焊接成一体。
叶轮通过超声波焊接工艺成型，将叶片与叶轮转子组件二通过超声波焊接成一体；叶轮一体注塑成型的注塑模具结构复杂，维护成本高，因此将叶轮分成叶轮主体和叶片两个部件分别注塑成型，再用超声波焊接进行成型，注塑模具的结构简单，大大降低了注塑模具的维护成本。
在上述技术方案中，优选地，所述轴套的耐磨性能优于所述叶轮主体的耐磨性能。
叶轮转子组件通过两步注塑工艺成型，第一步注塑成型叶轮主体，第二步注塑成型轴套，这样叶轮主体和轴套各自注塑成型时所用的注塑材料可以不同，注塑叶轮主体的材料要求为高强度、耐酸碱，注塑轴套的材料要求为耐磨、高强度、耐酸碱，注塑轴套所用的材料成本高，注塑叶轮主体所用的材料成本低，相比于轴套与叶轮主体一体注塑的叶轮转子组件，节省了制造成本。
在上述任一技术方案中，优选地，所述机壳组件的机壳注塑体的前端与所述泵壳之间装设有第一密封圈，形成密闭的水力空腔；所述机壳组件的机壳注 塑体的后端与所述后端盖之间装设有第二密封圈，形成密闭的电控腔体。
控制部的控制板装设于机壳与后端盖围成的电控腔体内部，无刷电机部装设于水利部和控制部之间；无刷电机部的定子组件一体注塑而成，且与机壳二次注塑成型；无刷电机部的机壳与泵壳、无刷电机部的机壳与后端盖之间分别装设有密封圈，实现该电子水泵的密封。
在上述任一技术方案中，优选地，所述水力部和所述无刷电机部通过螺钉固定连接，所述无刷电机部和所述控制部通过螺钉固定连接，装配方便，连接牢固。
本申请的附加方面和优点将在下面的描述部分中变得明显，或通过本申请的实践了解到。
附图说明
本申请的上述和/或附加的方面和优点从结合下面附图对实施例的描述中将变得明显和容易理解，其中：
图1是本申请一个实施例的定子组件的剖视结构示意图；
图2是本申请一个实施例的机壳组件的剖视结构示意图；
图3是本申请一个实施例的电子水泵的剖视结构示意图；
图4是本申请一个实施例的叶轮转子组件的剖视结构示意图。
其中，图1至图4中的附图标记与部件名称之间的对应关系为：
1机壳组件，11定子组件，111插针，112绕组，113定子铁芯，114定子注塑体，115绝缘框架，12转轴，13轴底座，14机壳注塑体，2泵壳，3叶轮转子组件，31轴套，32磁钢，33转子铁芯，34叶轮主体，35叶片，4第一密封圈，5第二密封圈，6控制板，7后端盖。
具体实施方式
为了能够更清楚地理解本申请的上述目的、特征和优点，下面结合附图和具体实施方式对本申请进行进一步的详细描述。需要说明的是，在不冲突的情况下，本申请的实施例及实施例中的特征可以相互组合。
在下面的描述中阐述了很多具体细节以便于充分理解本申请，但是，本申 请还可以采用其他不同于在此描述的其他方式来实施，因此，本申请的保护范围并不受下面公开的具体实施例的限制。
下面参照图1至图4描述根据本申请一些实施例所述的电子水泵及其机壳组件。
如图2和图3所示，根据本申请的一些实施例提供的一种电子水泵的机壳组件1，包括定子组件11、转轴12、轴底座13和机壳注塑体14，定子组件11整体注塑而成，机壳组件1二次注塑而成，转轴12与轴底座13过盈配合，转轴12和轴底座13均嵌入机壳注塑体14内部，定子组件11包裹于机壳注塑体14内部形成自密封。
本申请上述实施例提供的电子水泵的机壳组件1，将定子组件11整体注塑而成，再将定子组件11与机壳二次注塑成型，与转子实现自密封作用，省去了定转子气隙间的隔离套，降低了机壳材料成本，同时简化了电子水泵的装配工艺，并使得定子组件11的刚度提升，有利于电子水泵噪音的改善，提高了电子水泵运行的可靠性，因此上述方案的电子水泵的机壳组件1，在安装工艺、成本以及性能上均具有明显的优势。
其次，先整体注塑成型定子组件11，再二次注塑成型机壳组件1，这样注塑定子组件11的定子注塑体114和注塑机壳组件1的机壳注塑体14可以采用不同注塑料，机壳注塑体14要求的强度高，可以采用成本较高的注塑料，而定子注塑体114要求的强度低，可以采用成本较低的注塑料，相较于相关技术中定子注塑层作为电机壳体，上述方案既保证了机壳注塑体14的强度，又节省了材料成本；再次，将定子注塑体114和机壳注塑体14分别注塑成型，使得定子注塑体114的体积较小，注塑成型时间较短，注塑定子注塑体114时不会对定子注塑体114内部的绕组112等部件造成损坏，从而确保电子水泵的性能可靠性。
在本申请的一个实施例中，如图1所示，定子组件11包括插针111、绕组112、绝缘框架115、定子铁芯113和定子注塑体114，绝缘框架115包裹定子铁芯113，绕组112缠绕于绝缘框架115的齿部，插针111固定于绝缘框架115的凹槽内，定子注塑体114将插针111、绕组112、绝缘框架115和定子铁芯113包裹紧固，利用定子注塑体114将定子组件11的整个部件包裹紧 固，从而将定子组件11整体注塑为一体。
优选地，定子组件11包括定子注塑体114，定子注塑体114为热固性材料，热固性材料的固性变形温度不低于机壳注塑体14的注塑温度。
定子注塑体114采用热固性材料，优选采用BMC热固性材料，材料成本低；热固性材料的固性变形温度不低于机壳注塑体14的注塑温度，以避免二次注塑机壳组件1时熔融一次注塑成型的定子注塑体114的风险。
优选地，定子组件11包括定子注塑体114，定子注塑体114为热固性材料，机壳注塑体14为PPS材料。
定子注塑体114采用成本较低的热固性材料，优选采用BMC热固性材料，机壳注塑体14采用强度较高的PPS材料，既保证机壳注塑体14的强度，又节省了材料成本。
如图3所示，本申请第二方面的实施例提供了一种电子水泵，包括水力部、无刷电机部及控制部，水力部包括泵壳2及叶轮；无刷电机部包括转子和如上述任一实施例的机壳组件1；控制部包括控制板6和后端盖7；无刷电机部装设于水力部和控制部之间。
本申请上述实施例提供的电子水泵，因其包括上述任一实施例的机壳组件1，因而具有上述任一实施例的机壳组件1的有益效果，在此不再赘述。
优选地，如图3和图4所示，叶轮和转子一体注塑而成成为叶轮转子组件3。
水力部的叶轮与无刷电机部的转子一体注塑而成，分别装设于泵壳2与机壳内部，使得叶轮转子组件3的制造方便，成本低。
在本申请的一个实施例中，如图4所示，叶轮包括叶轮主体34和叶片35，转子包括转子铁芯33、磁钢32和轴套31，转子铁芯33上设有磁钢32槽，磁钢32安装在磁钢32槽内，转子铁芯33和磁钢32塑封在叶轮主体34内部成为叶轮转子组件一，轴套31二次注塑于叶轮转子组件一中成为叶轮转子组件二，叶轮转子组件二与叶片35相连成为叶轮转子组件3。
上述方案的叶轮转子组件3，包括叶轮和转子两部分，叶轮包括叶轮主体34、叶片35；转子包括转子铁芯33、磁钢32、轴套31，叶轮转子组件3通过两步注塑工艺成型，第一步注塑成型叶轮主体34，第二步注塑成型轴套31， 这样叶轮主体34和轴套31各自注塑成型时所用的注塑材料可以不同，注塑叶轮主体34的材料要求为高强度、耐酸碱，注塑轴套31的材料要求为耐磨、高强度、耐酸碱，注塑轴套31所用的材料成本高，注塑叶轮主体34所用的材料成本低，相比于轴套31与叶轮主体34一体注塑的叶轮转子组件3，节省了制造成本；其次，铁芯、磁钢32塑封在叶轮主体34内，粘接牢固；轴套31体积小，重量轻，叶轮转子组件3在旋转时，带动轴套31旋转的扭矩小，轴套31不易打滑；再次，叶轮主体34体积大，轴套31体积小，注塑轴套31时速度快，不会对叶轮转子组件一造成影响，也即在二次注塑成型轴套31时不会熔融第一次注塑成型的叶轮主体，因此很好地避免了铁芯和磁钢32移位的风险。
进一步地，如图4所示，叶片35为注塑体，叶轮转子组件二与叶片35通过超声波焊接成一体，成为叶轮转子组件3。
叶轮通过超声波焊接工艺成型，将叶片35与叶轮转子组件二通过超声波焊接成一体；叶轮一体注塑成型的注塑模具结构复杂，维护成本高，因此将叶轮分成叶轮主体34和叶片35两个部件分别注塑成型，叶片35上设置有焊线，叶轮主体34上设置有焊接槽，再用超声波焊接进行成型，注塑模具的结构简单，大大降低了注塑模具的维护成本。
具体地，机壳组件1的机壳注塑体14的前端与泵壳2之间装设有第一密封圈4，形成密闭的水力空腔；机壳组件1的机壳注塑体14的后端与后端盖7之间装设有第二密封圈5，形成密闭的电控腔体。
控制部的控制板6装设于机壳与后端盖7围成的电控腔体内部，电机部通过设置控制板6实现电流的换向，从而保证电机持续转动；无刷电机部装设于水利部和控制部之间；无刷电机部的定子组件11一体注塑而成，且与机壳二次注塑成型；无刷电机部的机壳与泵壳2、无刷电机部的机壳与后端盖7之间分别装设有密封圈，实现该电子水泵的密封。
优选地，水力部和无刷电机部通过螺钉固定连接，无刷电机部和控制部通过螺钉固定连接，装配方便，连接牢固。
一个具体实施例中，如图3所示，电子水泵包括水力部，无刷电机部及控制部；水力部的叶轮与无刷电机部的转子一体注塑而成，并分别装设于泵壳2 与机壳内部；控制部的控制板6装设于机壳与后端盖7围成的电控腔体内部，无刷电机部装设于水力部和控制部之间；无刷电机部的定子组件11一体注塑而成，且与机壳二次注塑成型；无刷电机部的机壳与泵壳2、无刷电机部的机壳与后端盖7之间分别装设有密封圈，实现该电子水泵的密封；上述方案利用定子与机壳的整体注塑技术不仅节省了传统电子水泵机壳的材料成本，也省去了定转子气隙中间的隔离套，同时简化了电子水泵的安装工艺；此外，定子刚度的提升也有利于电子水泵噪音的改善，因此，上述方案在安装工艺、成本以及性能上均具有显著的优势。
具体地，电子水泵为车用电子水泵。
本申请的描述中，需要理解的是，术语“内”、“外”等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本申请和简化描述，而不是指示或暗示所指的装置或单元必须具有特定的方向、以特定的方位构造和操作，因此，不能理解为对本申请的限制。
在本申请的描述中，除非另有明确的规定和限定，术语“相连”、“连接”、“固定”等均应做广义理解，例如，“连接”可以是固定连接，也可以是可拆卸连接，或一体地连接，或电连接；可以是直接相连，也可以通过中间媒介间接相连。对于本领域的普通技术人员而言，可以根据具体情况理解上述术语在本申请中的具体含义。
在本说明书的描述中，术语“一个实施例”、“一些实施例”、“具体实施例”等的描述意指结合该实施例或示例描述的具体特征、结构、材料或特点包含于本申请的至少一个实施例或示例中。在本说明书中，对上述术语的示意性表述不一定指的是相同的实施例或实例。而且，描述的具体特征、结构、材料或特点可以在任何的一个或多个实施例或示例中以合适的方式结合。
以上所述仅为本申请的优选实施例而已，并不用于限制本申请，对于本领域的技术人员来说，本申请可以有各种更改和变化。凡在本申请的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本申请的保护范围之内。

Claims (13)

  1. 一种电子水泵的机壳组件，其中，
    所述机壳组件包括定子组件和机壳注塑体，所述定子组件整体注塑而成，所述机壳组件二次注塑而成，所述定子组件包裹于所述机壳注塑体内部形成自密封。
  2. 一种电子水泵的机壳组件，其中，
    所述机壳组件包括定子组件、转轴、轴底座和机壳注塑体，所述定子组件整体注塑而成，所述机壳组件二次注塑而成，所述转轴和所述轴底座均嵌入所述机壳注塑体内部，所述定子组件包裹于所述机壳注塑体内部形成自密封。
  3. 根据权利要求1或2所述的电子水泵的机壳组件，其中，
    所述定子组件包括插针、绕组、绝缘框架、定子铁芯和定子注塑体，所述绝缘框架包裹所述定子铁芯，所述绕组缠绕于所述绝缘框架的齿部，所述插针固定于所述绝缘框架的凹槽内，所述定子注塑体将所述插针、所述绕组、所述绝缘框架和所述定子铁芯包裹紧固。
  4. 根据权利要求1或2所述的电子水泵的机壳组件，其中，
    所述定子组件包括定子注塑体，所述定子注塑体为热固性材料，所述热固性材料的固性变形温度不低于所述机壳注塑体的注塑温度。
  5. 根据权利要求1或2所述的电子水泵的机壳组件，其中，
    所述定子组件包括定子注塑体，所述定子注塑体为热固性材料，所述机壳注塑体为PPS材料。
  6. 根据权利要求1或2所述的电子水泵的机壳组件，其中，
    所述定子组件包括定子注塑体，所述机壳注塑体的材料强度大于所述定子注塑体的材料强度。
  7. 一种电子水泵，包括水力部、无刷电机部及控制部，其中，
    所述水力部包括泵壳及叶轮；
    所述无刷电机部包括转子和如权利要求1至6中任一项所述的机壳组件；
    所述控制部包括控制板和后端盖；
    所述无刷电机部装设于所述水力部和所述控制部之间。
  8. 根据权利要求7所述的电子水泵，其中，
    所述叶轮和所述转子一体注塑而成成为叶轮转子组件。
  9. 根据权利要求8所述的电子水泵，其中，
    所述叶轮包括叶轮主体和叶片，所述转子包括转子铁芯、磁钢和轴套，所述转子铁芯上设有磁钢槽，所述磁钢安装在所述磁钢槽内，所述转子铁芯和所述磁钢塑封在所述叶轮主体内部成为叶轮转子组件一，所述轴套二次注塑于所述叶轮转子组件一中成为叶轮转子组件二，所述叶轮转子组件二与所述叶片相连成为所述叶轮转子组件。
  10. 根据权利要求9所述的电子水泵，其中，
    所述叶片为注塑体，所述叶轮转子组件二与所述叶片通过超声波焊接成一体。
  11. 根据权利要求9所述的电子水泵，其中，
    所述轴套的耐磨性能优于所述叶轮主体的耐磨性能。
  12. 根据权利要求7至11中任一项所述的电子水泵，其中，
    所述机壳组件的机壳注塑体的前端与所述泵壳之间装设有第一密封圈，形成密闭的水力空腔；
    所述机壳组件的机壳注塑体的后端与所述后端盖之间装设有第二密封圈，形成密闭的电控腔体。
  13. 根据权利要求7至11中任一项所述的电子水泵，其中，
    所述水力部和所述无刷电机部通过螺钉固定连接，所述无刷电机部和所述控制部通过螺钉固定连接。
PCT/CN2019/094988 2018-08-31 2019-07-08 电子水泵及其机壳组件 WO2020042761A1 (zh)

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