WO2024099317A1 - 用于无刷电机的连接结构和无刷电机 - Google Patents

用于无刷电机的连接结构和无刷电机 Download PDF

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Publication number
WO2024099317A1
WO2024099317A1 PCT/CN2023/130248 CN2023130248W WO2024099317A1 WO 2024099317 A1 WO2024099317 A1 WO 2024099317A1 CN 2023130248 W CN2023130248 W CN 2023130248W WO 2024099317 A1 WO2024099317 A1 WO 2024099317A1
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WIPO (PCT)
Prior art keywords
coil
contact section
brushless motor
connection structure
contact
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PCT/CN2023/130248
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English (en)
French (fr)
Inventor
陈亮
谢小五
张宏亮
江远
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广东肇庆爱龙威机电有限公司
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Publication of WO2024099317A1 publication Critical patent/WO2024099317A1/zh

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/24—Connections using contact members penetrating or cutting insulation or cable strands
    • H01R4/2404—Connections using contact members penetrating or cutting insulation or cable strands the contact members having teeth, prongs, pins or needles penetrating the insulation
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K29/00—Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/28—Layout of windings or of connections between windings

Definitions

  • the present invention relates to the technical field of motors, and in particular to a connection structure for a brushless motor and a brushless motor comprising the connection structure.
  • a brushless motor generally includes a stator assembly and a rotor assembly, wherein the stator assembly includes a stator and a stator winding wound on the stator, and the stator winding can realize the power transmission of the motor by being electrically connected to a PCB board.
  • the lacquered wire of the stator winding and the PCB board are connected by manual soldering to ensure circuit connectivity.
  • a connection structure for a brushless motor comprising a stator assembly and a rotor assembly, wherein the stator assembly comprises a stator and a stator winding wound on the stator, wherein the stator winding is One axial end is electrically connected to a PCB board to achieve power transmission via the PCB board, the connection structure includes a first contact section and a second contact section, the first contact section is intended to electrically contact the coil of the stator winding, and the second contact section is intended to electrically contact the PCB board, so that the electrical connection between the stator winding and the PCB board can be achieved via the connection structure, wherein the first contact section includes a wire breaking portion for piercing the insulating outer skin of the coil and a clamping portion for clamping and holding the metal wire of the coil.
  • connection structure further comprises a middle section for connecting the first contact section and the second contact section, and an outermost edge of the middle section exceeds the first contact section.
  • the first contact section includes two contact arms spaced apart from each other, and a space for the coil to pass through is defined between the two contact arms.
  • a pair of first protrusions are relatively arranged on the inner edges of the two contact arms facing each other, and a first width is defined between the pair of first protrusions, which is smaller than the outer diameter of the coil, so that the coil is pierced through the insulating sheath by the pair of first protrusions when entering the space.
  • a pair of second protrusions are oppositely arranged on the inner edges of the two contact arms facing each other, and a second width is defined between the pair of second protrusions, which is smaller than the first width, so that the metal wire of the coil is clamped and held by the pair of second protrusions.
  • a pair of third protrusions are provided on the first contact section, and the third protrusions are intended to be interference-fitted with the receiving groove for receiving the first contact section.
  • the second contact section is formed in the form of a fisheye pin, which is suitable for press-fitting with a tin-plated hole reserved on the PCB board.
  • a brushless motor comprising a plurality of the above-mentioned connection structures.
  • the brushless motor comprises a plurality of insulating sleeves arranged at the axial ends of the stator winding, each insulating sleeve is provided with a receiving slot, and a portion of the coil of the stator winding passes through the receiving slot.
  • the first contact section of the connecting structure is intended to be press-fitted into the corresponding receiving groove so that during the press-in process the insulating sheath of the coil is pierced by the wire-breaking portion and the coil is clamped by the clamping portion.
  • the holding portion clamps and holds the metal wire of the coil.
  • connection structure for a brushless motor and the brushless motor including the connection structure according to the present invention can achieve at least one of the following technical effects: a reliable circuit connection method between a winding coil and a PCB board can be provided when the soldering process cannot be implemented or is inconvenient to implement due to limited motor size and space; the structural requirements of different working current sizes can be adapted while achieving reliable circuit connection; the soldering process between the coil (such as varnished wire) and the PCB board is omitted, the operability is relatively good, the process is relatively simple, and it is easy to automate production.
  • FIG1 is a schematic structural diagram showing a connection structure for a brushless motor according to the present invention.
  • FIG. 2a shows a three-dimensional schematic diagram of a brushless motor according to the present invention (on which a PCB board is not installed);
  • FIG. 2b shows a three-dimensional schematic diagram of a brushless motor according to the present invention (on which a PCB board is installed);
  • FIG. 3a partially shows in cross-section an insulating sleeve provided at an axial end of the winding of the brushless motor shown in FIGS. 2a and 2b;
  • FIG. 3b shows a schematic diagram of the connection structure shown in FIG. 1 being press-fitted into the insulating sleeve;
  • FIG. 4 shows the clamping relationship between the winding coil and the connection structure.
  • DC motors can be classified into DC motors and AC motors according to the type of working power supply.
  • DC motors usually include brushed DC motors and brushless DC motors.
  • Brushed DC motors use mechanical commutation, with the external magnetic poles stationary and the internal coils moving. When the motor is working, the commutator and the coils rotate together, and the carbon brushes and the magnets are stationary, so the commutator and the carbon brushes produce friction to complete the switching of the current direction.
  • Brushless DC motors use electronic commutation, without commutators and carbon brushes, but with position sensors. They are mainly composed of a permanent magnet rotor, a multi-pole winding stator and a position sensor.
  • the position sensor energizes the adjacent stator coils according to the magnetic pole position of the rotor, allowing the stator to generate magnetic poles that are attracted to the rotor, thereby attracting the rotor to rotate, and this is repeated to drive the motor to rotate.
  • connection structure according to the present invention (which will be discussed in detail below) is mainly used in brushless motors.
  • the stator winding of a brushless motor is usually a three-phase winding.
  • the stator winding electrically connects the coils of each phase winding to the PCB board at one of the axial ends.
  • the coils in the form of lacquered wire of the stator winding and the PCB board are connected by manual soldering to ensure circuit connectivity.
  • the soldering process cannot be implemented or is inconvenient to implement, which requires a reliable and effective way to achieve the circuit connection of the motor.
  • the present invention proposes an improved structure, which relates to a connection structure for windings, especially for brushless motors, and which can reliably realize circuit connection of the motor when a soldering process cannot be performed.
  • connection structure 100 may be formed in the form of a metal connection sheet (e.g., a copper sheet material such as C19010 or similar tin bronze), which includes a first contact section 110, a second contact section 120, and an intermediate section 130 for connecting the first contact section 110 and the second contact section 120.
  • the first contact section 110 is intended to be in electrical contact with the coil 400 of the stator winding
  • the second contact section 120 is intended to be in electrical contact with the PCB board 200, so that the stator winding can be electrically connected to the PCB board 200 via the connection.
  • the connection structure 100 realizes the electrical connection between the stator winding and the PCB board 200 .
  • connection structure 100 of the present invention can omit the soldering process between the winding coil and the PCB board.
  • the first contact section 110 advantageously includes a wire-breaking portion for piercing the insulating outer skin of the coil and a clamping portion for clamping and holding the exposed metal wire of the coil. In this way, in the process of pressing the connection structure 100 into, for example, an insulating sleeve 300 (which is provided with a receiving groove 301, see FIG.
  • the insulating outer skin of the coil will first be pierced by the wire-breaking portion, and the exposed metal wire (such as copper wire) will finally be clamped and held by the clamping portion.
  • the wire-breaking portion and the clamping portion can have a variety of different structural forms, as long as the above functions can be achieved.
  • the first contact section 110 includes two contact arms 111 spaced apart from each other and preferably symmetrically arranged, the two contact arms 111 extending from the middle section 130 in a direction away from the second contact section 120, and defining a space 112 for the winding coil to pass therethrough between the two contact arms 111.
  • a pair of first protrusions 111a are oppositely or symmetrically arranged on the inner edges of the two contact arms facing each other, and a first width W1 is defined between the pair of first protrusions 111a, which is smaller than the outer diameter of the coil, so that when the corresponding coil is initially pressed into the space 112, the insulating outer skin of the coil is pierced by the pair of first protrusions 111a.
  • a second width W2 is defined between the pair of second protrusions 111b, which is smaller than the outer diameter of the coil and the first width W1, thereby allowing the metal wire of the coil to be clamped and held by the pair of second protrusions 111b (see FIG. 4).
  • the second contact section 120 can be formed in the form of a fisheye pin (see FIG. 1 ), which is suitable for press-fitting with the tin-plated hole 201 reserved on the PCB board 200 (see FIG. 2 b ).
  • the electrical connection between the winding coil and the PCB can be simply achieved through the above connection structure, without the need to implement a cumbersome and complicated soldering process between the winding coil and the PCB board.
  • the brushless motor may include a plurality of insulating sleeves 300 disposed at the axial end of the stator winding, and the insulating sleeves 300 may be integrally formed or individually formed.
  • a receiving slot 301 is provided on the insulating sleeve 300, and a portion of the coil of the corresponding phase winding of the stator winding passes through one of the receiving slots 301.
  • the first contact section 110 of the connection structure 100 is intended to be press-fitted into the receiving groove 301 of the insulating sleeve 300.
  • the insulating outer skin of the coil 400 will be pierced by the wire-breaking portion (first protrusion 111a), and the exposed metal wire is then clamped and held by the clamping portion (second protrusion 111b).
  • the outermost edge of the middle section 130 of the connection structure is designed to exceed the first contact section 110 , when the pressing process is completed, the lower edge 131 of the middle section 130 will stop on the insulating sleeve 300 .
  • a pair of third protrusions 111c may be further provided on the first contact section 110.
  • a pair of third protrusions in the form of barbs are provided on the outer edges of the two contact arms 111 that are away from each other, and the barbs define a third width W3 that is greater than the inner hole diameter of the receiving groove 301 (see FIG. 3b ), so as to ensure that the connection structure 100 can be interference-fitted in the receiving groove 301 by using the third protrusions.
  • the above-mentioned connecting structure can not only pierce the insulating outer skin by the pressing action, but also be stably maintained in the receiving groove while ensuring the electrical contact between the connecting structure and the exposed metal wire.
  • the second contact section is crimped onto the PCB board and electrically connected thereto, so that the welding process is replaced by simple operating steps, and the circuit connection of the motor is reliably realized.
  • FIG. 2a-2b A brushless motor with a star-connected winding is shown in Figures 2a-2b.
  • three connection structures 100 discussed above are provided, which are respectively inserted into the receiving slots of the corresponding insulating sleeves and are in electrical contact with the coils of the corresponding phase windings passing through the receiving slots.
  • a similar connection structure 100' can also be provided to achieve the common end connection of the three-phase windings.
  • connection structure 100' can also include similar wire breaking portions and clamping portions at each terminal electrically connected to the winding coil, so that the common end welding process can be omitted. If the connection structure 100' When it is needed to be used in conjunction with the PCB board 200, a fisheye pin can also be formed thereon to facilitate electrical connection of the PCB board.
  • connection structure of the present invention since the connection structure of the present invention does not need to rely on the soldering process to achieve the circuit connection between the winding and the PCB board, various motor operating currents can be used without considering the impact of the diameter of the paint wire on the soldering process.
  • the width A of the second contact section 120, such as the fisheye pin, in the connection structure according to the present invention can be selected according to the magnitude of the working current of the motor, thereby allowing the structural requirements of different working current magnitudes to be adapted. Accordingly, the size of the tin-plated hole 201 reserved on the PCB board 200 for matching with the fisheye pin can be selected according to the width A to ensure a press-fit relationship between the two.
  • the connecting structure according to the present invention When the connecting structure according to the present invention is pressed into the receiving groove of the insulating sleeve, the insulating outer skin of the coil is pierced by the wire breaking part and the metal wire of the coil is clamped and stably held by the clamping part, so that the soldering process between the winding coil of the brushless motor and the PCB board can be replaced.
  • This solves the circuit connection problem of the motor when the soldering process cannot be or is inconvenient to implement due to limited space in a compact motor structure with a smaller size. It has good operability, saves processes and manpower, and is easier to automate production.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)

Abstract

本发明涉及一种用于无刷电机的连接结构，无刷电机包括定子组件和转子组件，定子组件包括定子和定子绕组，定子绕组在一轴向端处与PCB板电连接以经由PCB板实现电力传输，连接结构包括第一接触部段和第二接触部段，第一接触部段旨在与定子绕组的线圈电接触，第二接触部段旨在与PCB板电接触，使得能经由连接结构实现定子绕组与PCB板之间的电连接，第一接触部段包括用于刺破线圈的绝缘外皮的破线部和用于夹紧并保持线圈的金属导线的夹持部。本发明还涉及一种包括上述连接结构的无刷电机。在尺寸较小的电机结构中，根据本发明的连接结构解决了电机在因空间有限而无法实施焊锡工序的情况下的电路连接问题，节省了工序和人力，更易于自动化生产。

Description

用于无刷电机的连接结构和无刷电机 技术领域
本发明涉及电机技术领域，具体地涉及一种用于无刷电机的连接结构以及包括这种连接结构的无刷电机。
背景技术
随着科学技术的发展，为了尽可能地满足汽车用户的需要且提高用户的使用舒适度，在汽车中集成有越来越多的功能。为了实现这些功能，电机、尤其是无刷直流电机在汽车领域中被广泛地应用。
无刷电机通常包括定子组件和转子组件，其中定子组件包括定子和缠绕在定子上的定子绕组，定子绕组可通过与PCB板电连接来实现电机的电力传输。在现有的无刷电机设计中，特别是在尺寸比较小的电机结构中，定子绕组的漆皮线和PCB板是通过人工焊锡连接来保证电路连通的。
然而，当要求电机被设计成具有非常小的尺寸时，常常会存在如下的问题：在PCB板被安装后，受限于电机的尺寸设计，往往没有空间供烙铁进入以实施焊锡或者无法便利地操作焊锡工序；或者，当电机工作电流比较大时，由于绕组的漆皮线的线径比较大，导致难以在PCB板上实施焊锡。另外，由于现有技术中常常需要人工焊锡，人力资源占比重，工艺相对复杂，生产效率较低，且难以实现自动化生产。
因而，需要提出一种新的无刷电机结构，使其能够克服上述一个或多个问题和/或现有技术中存在的其它缺陷。
发明内容
本发明便是基于这样的背景而提出的。根据本发明的一个方面，其提供了一种用于无刷电机的连接结构，所述无刷电机包括定子组件和转子组件，所述定子组件包括定子和缠绕在定子上的定子绕组，所述定子绕组在 一轴向端处与PCB板电连接以经由该PCB板实现电力传输，所述连接结构包括第一接触部段和第二接触部段，所述第一接触部段旨在与所述定子绕组的线圈电接触，所述第二接触部段旨在与所述PCB板电接触，使得能够经由所述连接结构实现所述定子绕组与所述PCB板之间的电连接，其中，所述第一接触部段包括用于刺破所述线圈的绝缘外皮的破线部和用于夹紧并保持所述线圈的金属导线的夹持部。
有利地，所述连接结构还包括用于连接所述第一接触部段与所述第二接触部段的中间部段，该中间部段的最外边缘超出所述第一接触部段。
有利地，所述第一接触部段包括彼此间隔开地设置的两个接触臂，在所述两个接触臂之间界定有供所述线圈穿过其中的空间。
有利地，在所述两个接触臂的彼此面对的内边缘上相对地设置有一对第一凸起，在所述一对第一凸起之间限定有第一宽度，该第一宽度小于所述线圈的外径，使得所述线圈在进入至所述空间中时由所述一对第一凸起刺破绝缘外皮。
有利地，在所述两个接触臂的彼此面对的内边缘上相对地设置有一对第二凸起，在所述一对第二凸起之间限定有第二宽度，该第二宽度小于所述第一宽度，使得由所述一对第二凸起夹紧并保持所述线圈的金属导线。
有利地，在所述第一接触部段上设置有一对第三凸起，所述第三凸起旨在与用于接纳所述第一接触部段的接纳槽过盈配合。
有利地，所述第二接触部段形成为鱼眼插针的形式，该鱼眼插针适于与所述PCB板上预留的镀锡孔压配合。
根据本发明的另一个方面，其提供了一种无刷电机，所述无刷电机包括多个上述连接结构。
有利地，所述无刷电机包括设置在所述定子绕组的所述轴向端处的多个绝缘套，在每个绝缘套上开设有接纳槽，所述定子绕组的线圈的一部分穿过所述接纳槽。
有利地，所述连接结构的第一接触部段旨在被压配合在相应的接纳槽中，使得在压入过程中通过所述破线部刺破线圈的绝缘外皮且通过所述夹 持部夹紧并保持线圈的金属导线。
与现有技术相比，采用根据本发明的用于无刷电机的连接结构和包括该连接结构的无刷电机，能够至少实现以下技术效果之一：可以在因电机尺寸空间受限导致焊锡工序无法实现或者不方便实施的情况下提供一种绕组线圈与PCB板之间的可靠的电路连接方式；可以在实现电路可靠连接的同时适应不同工作电流大小的结构需求；省去了线圈(如漆皮线)与PCB板之间的焊锡工序，可操作性比较好，工艺相对简单，易于自动化生产。
附图说明
通过以下参照附图的描述，本发明的上述和其它特征和优点将变得更加容易理解，其中：
图1示出根据本发明的用于无刷电机的连接结构的结构示意图；
图2a示出根据本发明的无刷电机(其上未安装PCB板)的立体示意图；图2b示出根据本发明的无刷电机(其上安装有PCB板)的立体示意图；
图3a以截面图部分地示出在图2a和2b中所示的无刷电机的绕组的一轴向端处设置的绝缘套；图3b示出图1所示的连接结构被压配合在绝缘套中时的示意图；以及
图4示出绕组线圈与连接结构之间的夹持关系。
所有附图都只是示意性的，而且并不一定按比例绘制，此外它们仅示出为了阐明本发明而必需的那些部分，其他部分被省略或仅仅提及。即，除附图中所示出的部件外，本发明还可以包括其他部件。
具体实施方式
在下面的描述中，阐述了许多具体细节以便使所属技术领域的技术人员更全面地了解本发明。但是，对于所属技术领域内的技术人员明显的是，本发明的实现可不具有这些具体细节中的一些。下面的各个方面、特征、实施例和优点仅作说明之用而不应被看作是权利要求的要素或限定，除非 在权利要求中明确提出。在下文中使用了例如“第一”、“第二”等术语来描述本申请的元件，这些术语仅用于区分各个元件，而无欲限制这些元件的本质、序列、顺序或数目。另外，需指出，在本说明书中，相同的和/或功能相同的技术特征采用相同或相似的附图标记。
电机按工作电源种类可以分类为直流电机和交流电机，其中直流电机通常包括有刷直流电机和无刷直流电机，其中，有刷直流电机是采用机械换向，外部磁极不动而内部线圈动，电机工作时，换向器和线圈一起旋转，碳刷与磁钢都不动，于是换向器和碳刷产生摩擦，完成电流方向切换；而无刷直流电机是采用电子换向，没有换向器和碳刷，而是使用的位置传感器，其主要由永磁体转子、多极绕组定子和位置传感器等组成，位置传感器根据转子的磁极位置，给相邻的定子线圈通电，让定子产生与转子相吸的磁极，就能吸引转子转动，如此重复以推动电机转动。
根据本发明的连接结构(将在下文中详细讨论)主要应用于无刷电机中。无刷电机的定子绕组通常为三相绕组。为了实现电机的电力传输，定子绕组在其中一个轴向端处将各相绕组的线圈与PCB板电连接。在现有的无刷电机设计中，特别是在尺寸比较小的电机结构中，定子绕组的漆皮线形式的线圈与PCB板是通过人工焊锡连接来保证电路连通的。如背景技术部分中提及的，由于电机尺寸空间受限，常常存在焊锡工序无法实现或者不方便实施的情况，这使得需要一种可靠有效的方式来实现电机的电路连接。
为此，本发明提出了一种改进的结构，其涉及一种尤其用于无刷电机的绕组的连接结构，其能够在无法实施焊锡工序的情况下可靠地实现电机的电路连接。
具体地，如图1所示，该连接结构100可形成为金属连接片(例如C19010或者类似的锡青铜等的铜片材料)的形式，其包括第一接触部段110、第二接触部段120以及用于连接所述第一接触部段110与所述第二接触部段120的中间部段130。第一接触部段110旨在与定子绕组的线圈400电接触，第二接触部段120旨在与PCB板200电接触，使得能经由所述连 接结构100实现所述定子绕组与所述PCB板200之间的电连接。
与现有技术中的方案不同的是，采用本发明的连接结构100，可以省去绕组线圈与PCB板之间的焊锡工序。具体地，第一接触部段110有利地包括用于刺破所述线圈的绝缘外皮的破线部和用于夹紧并保持线圈的裸露的金属导线的夹持部。如此，在将连接结构100压入至例如形成在定子绕组的轴向端处的绝缘套300(其开设有接纳槽301，见图3a)内的过程中，线圈的绝缘外皮将首先由破线部刺破，露出的金属导线(如铜线)最后由夹持部夹紧并保持。破线部和夹持部可以有多种不同的结构形式，只要能够实现上述功能即可。
根据如图1所示的示例性实施例，第一接触部段110包括彼此间隔开且优选对称地设置的两个接触臂111，这两个接触臂111自中间部段130朝向远离第二接触部段120的方向延伸，且在所述两个接触臂111之间界定有供绕组线圈穿过其中的空间112。在所述两个接触臂的彼此面对的内边缘上相对地或对称地设置有一对第一凸起111a，在所述一对第一凸起111a之间限定有第一宽度W1，该第一宽度W1小于所述线圈的外径，使得在相应的线圈最初被压入至所述空间112中时由所述一对第一凸起111a刺破所述线圈的绝缘外皮。
另外，随着线圈持续相对于两个接触臂111被压入至空间112中时，已被刺破的线圈的金属导线将由在两个接触臂111的彼此面对的内边缘上相对地或对称地设置的一对第二凸起111b夹紧。具体地，在所述一对第二凸起111b之间限定有第二宽度W2，该第二宽度W2小于所述线圈的外径和所述第一宽度W1，从而允许由所述一对第二凸起111b夹紧并保持线圈的金属导线(见图4)。
优选地，第二接触部段120可形成为鱼眼插针的形式(见图1)，该鱼眼插针适于与所述PCB板200上预留的镀锡孔201压配合(见图2b)。如此，可简单地通过上述连接结构实现绕组线圈与PCB之间电连接，而无需实施绕组线圈与PCB板之间繁冗和复杂的焊锡工序。
在定子绕组采用三相绕组的情况下，常常可设置有至少三个连接结构 100，其中，无刷电机可包括设置在所述定子绕组的所述轴向端处的多个绝缘套300，这些绝缘套300可一体成型或单独成型。在绝缘套300上开设有接纳槽301，所述定子绕组的相应相绕组的线圈的一部分穿过其中一个接纳槽301。
尤其参见图3b，连接结构100的第一接触部段110旨在被压配合在所述绝缘套300的接纳槽301中。随着第一接触部段110朝向接纳槽301中压入时，线圈400的绝缘外皮将由破线部(第一凸起111a)刺破，裸露的金属导线随后通过夹持部(第二凸起111b)夹紧并保持。
由于连接结构的中间部段130的最外边缘被设计成超出所述第一接触部段110，使得当压入过程结束时，该中间部段130的下侧边缘131将止挡在绝缘套300上。
为了使连接结构100能够被稳定地保持在接纳槽301中，在第一接触部段110上还可以设置有一对第三凸起111c。具体地，在两个接触臂111的彼此远离的外边缘上设置有一对倒钩部形式的第三凸起，该倒钩部限定了第三宽度W3，其大于接纳槽301的内孔直径(见图3b)，如此，确保该连接结构100能够利用所述第三凸起而过盈配合在该接纳槽301中。
如此，上述连接结构不仅能够借由压入动作刺破绝缘外皮，而且能够在确保连接结构与裸露的金属导线之间电接触的情况下被稳定地保持在接纳槽中，同时利用第二接触部段压接在PCB板上并与之电连接，使得以简单的操作步骤替代了焊接工序，可靠地实现了电机的电路连接。
本领域技术人员应了解的是，三相定子绕组可以采用星形连接和三角形连接。图2a-2b中示出了一种具有星形连接的绕组的无刷电机。在该无刷电机中，其设置有三个上述讨论的连接结构100，其分别被插入至对应设置的绝缘套的接纳槽中并且与穿过接纳槽的对应相绕组的线圈电接触。另外，为了实现绕组的星形连接，有利地，还可以设置一种类似的连接结构100’(见图2a)以实现三相绕组的公共端连接。这种连接结构100’如前述的连接结构100一样也可以在每个与绕组线圈电连接的接线端处包括类似的破线部和夹持部，使得能够省去公共端焊接工序。若该连接结构100’ 需要与PCB板200配合使用时，也可以在其上形成一个鱼眼插针以便于PCB板电连接。
作为本发明的一个改进点，由于本发明的连接结构无需依赖于焊锡工序来实现绕组与PCB板之间的电路连接，因此可以使用多种大小的电机工作电流，而不用考虑漆皮线的直径大小会对焊锡工序带来的影响。
根据本发明的连接结构中的第二接触部段120如鱼眼插针的宽度A可根据电机的工作电流的大小来选择，从而允许适应不同工作电流大小的结构需求。相应地，PCB板200上预留的旨在与鱼眼插针配合的镀锡孔201的尺寸可根据宽度A来选择，以确保两者之间的压配合关系。
在将根据本发明的连接结构压入到绝缘套的接纳槽内时，通过破线部刺破线圈的绝缘外皮且通过夹持部夹持且稳定保持线圈的金属导线，使得能够替代无刷电机的绕组线圈与PCB板之间的焊锡工序，这在尺寸较小的紧凑型电机结构中，解决了电机在因空间有限而无法或不方便实施焊锡工序的情况下的电路连接问题，具有很好的可操作性，节省了工序、人力，更易于自动化生产。
应当指出，上面说明的实施例仅应被视为示例性的，本发明不限于这些实施例。通过考虑本说明书的内容，本领域技术人员可在不偏离本发明的范围或精神的情况下做出多种改变和变型。本发明的真实范围由所附权利要求以及等同方案限定。

Claims (10)

  1. 一种用于无刷电机的连接结构(100)，所述无刷电机包括定子组件和转子组件，所述定子组件包括定子和缠绕在定子上的定子绕组，所述定子绕组在一轴向端处与PCB板(200)电连接以经由该PCB板实现电力传输，其特征在于，所述连接结构(100)包括第一接触部段(110)和第二接触部段(120)，所述第一接触部段旨在与所述定子绕组的线圈(400)电接触，所述第二接触部段旨在与所述PCB板(200)电接触，使得能够经由所述连接结构实现所述定子绕组与所述PCB板之间的电连接，其中，所述第一接触部段(110)包括用于刺破所述线圈(400)的绝缘外皮的破线部和用于夹紧并保持所述线圈(400)的金属导线的夹持部。
  2. 根据权利要求1所述的连接结构(100)，其特征在于，所述连接结构还包括用于连接所述第一接触部段(110)与所述第二接触部段(120)的中间部段(130)，该中间部段的最外边缘超出所述第一接触部段。
  3. 根据权利要求1所述的连接结构(100)，其特征在于，所述第一接触部段(110)包括彼此间隔开地设置的两个接触臂(111)，在所述两个接触臂之间界定有供所述线圈穿过其中的空间(112)。
  4. 根据权利要求3所述的连接结构(100)，其特征在于，在所述两个接触臂(111)的彼此面对的内边缘上相对地设置有一对第一凸起(111a)，在所述一对第一凸起之间限定有第一宽度(W1)，该第一宽度小于所述线圈的外径，使得所述线圈在进入至所述空间(112)中时由所述一对第一凸起(111a)刺破绝缘外皮。
  5. 根据权利要求4所述的连接结构(100)，其特征在于，在所述两个接触臂(111)的彼此面对的内边缘上相对地设置有一对第二凸起(111b)，在所述一对第二凸起之间限定有第二宽度(W2)，该第二宽度小于所述第一宽度，使得由所述一对第二凸起(111b)夹紧并保持所述线圈的金属导线。
  6. 根据权利要求1至5中任一项所述的连接结构(100)，其特征在于，在所述第一接触部段(110)上设置有一对第三凸起(111c)，所述第三凸起旨在与用于接纳所述第一接触部段的接纳槽(301)过盈配合。
  7. 根据权利要求1至5中任一项所述的连接结构(100)，其特征在于，所述第二接触部段(120)形成为鱼眼插针的形式，该鱼眼插针适于与所述PCB板(200)上预留的镀锡孔(201)压配合。
  8. 一种无刷电机，其特征在于，所述无刷电机包括多个根据权利要求1至7中任一项所述的连接结构(100)。
  9. 根据权利要求8所述的无刷电机，其特征在于，所述无刷电机包括设置在所述定子绕组的所述轴向端处的多个绝缘套(300)，在每个绝缘套上开设有接纳槽(301)，所述定子绕组的线圈的一部分穿过所述接纳槽。
  10. 根据权利要求9所述的无刷电机，其特征在于，每个连接结构(100)的第一接触部段(110)旨在被压配合在相应的接纳槽(301)中，使得在压入过程中通过所述破线部刺破线圈的绝缘外皮且通过所述夹持部夹紧并保持线圈的金属导线。
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