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KR-102963748-B1 - Stator core

KR102963748B1KR 102963748 B1KR102963748 B1KR 102963748B1KR-102963748-B1

Abstract

A stator core for a brushless permanent magnet motor has a back portion and a first arm and a second arm extending from the back portion. Each of the first arm and the second arm has a first portion extending substantially perpendicularly from the back portion and a second portion forming an oblique angle with respect to the first portion.

Inventors

  • 이페디, 추쿠마
  • 클로시어, 앤드류
  • 켈리크, 툰카이
  • 첸, 유

Assignees

  • 다이슨 테크놀러지 리미티드

Dates

Publication Date
20260512
Application Date
20220712
Priority Date
20210713

Claims (20)

  1. As a stator core for a brushless permanent magnet motor, It includes a back and a first arm and a second arm extending from the back, wherein each of the first arm and the second arm includes a first part extending perpendicularly from the back and a second part forming an oblique angle with respect to the first part. The above back part, the above first arm, and the above second arm define a winding channel for positioning a winding with respect to the stator core, and the winding channel includes a trapezoidal cross-sectional shape. Each second part includes its own pole face, and the pole faces of the first arm and the second arm are spaced apart from each other to define a slot gap, and The distance from the pole surface of the first arm to the centerline of the slot gap is different from the distance from the pole surface of the second arm to the centerline of the slot gap. Stator core.
  2. In Article 1, The second part of the first arm and the second arm tilts toward each other. Stator core.
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  4. In Article 1, The second part of the first arm and the second arm forms an angle of 20 to 40 degrees with respect to the respective first parts of the first arm and the second arm, Stator core.
  5. In Article 1, The length of each second part is 1.5 to 2.5 times the length of each first part, Stator core.
  6. In Article 1, The pole surfaces of the first arm and the second arm are asymmetrical, Stator core.
  7. In Article 6, The above polar surfaces are curved, and the center of curvature of the polar surface of the first arm is different from the center of curvature of the polar surface of the second arm. Stator core.
  8. In Article 6, The polar surface of the first arm has a shape different from the polar surface of the second arm, the polar surface of the first arm is asymmetric with respect to the centerline of the polar surface of the first arm, and the polar surface of the second arm is asymmetric with respect to the centerline of the polar surface of the second arm, Stator core.
  9. In Article 6, The ratio of the sum of the widths of the pole faces to the width of the slot gap is 3:1 to 7:1, Stator core.
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  11. In Article 1, The stator core comprises a plurality of interconnected laminations, and the second portion of the first arm and the second arm comprises protrusions to facilitate the connection of the plurality of laminations. Stator core.
  12. In Article 11, The above protrusion is located on a surface facing the outside of the second part, Stator core.
  13. In Article 1, The above back part is asymmetric with respect to the centerline of the above stator core, Stator core.
  14. A stator core for a brushless permanent magnet motor, and a bobbin overmolded into the stator core, The stator core comprises a back and a first arm and a second arm extending from the back, and each of the first arm and the second arm comprises a first portion extending perpendicularly from the back and a second portion forming an oblique angle with respect to the first portion. The above back part, the above first arm, and the above second arm define a winding channel for positioning a winding with respect to the stator core, and the winding channel includes a trapezoidal cross-sectional shape. The above bobbin includes a connecting portion for connecting to another bobbin of another stator core subassembly, Stator core sub-assembly.
  15. In Article 14, The above bobbin includes a winding guide portion for guiding a winding with respect to the bobbin, wherein the winding guide portion is located within a channel on a portion of the bobbin that is overlaid over the back portion of the stator core. Stator core subassembly.
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  17. In Article 14, The stator core subassembly comprises a winding that is wound onto the back portion of the stator core as it is wound onto the bobbin, and the winding has a trapezoidal cross-sectional shape on the inner surface of the back portion. Stator core subassembly.
  18. In Article 17, The above winding defines a different cross-sectional shape on the outer surface of the above back portion, Stator core subassembly.
  19. A stator assembly comprising a stator core subassembly according to claim 14.
  20. A brushless permanent magnet motor comprising a stator core according to any one of claims 1 to 2, 4 to 9 and 11 to 13, a stator core subassembly according to any one of claims 14, 15, 17 and 18, or a stator assembly according to claim 19.

Description

Stator core The present invention relates to a stator core for a brushless permanent magnet motor. In general, it is desirable to improve electric machines, such as brushless permanent magnet motors, in various aspects. For example, improvements may be needed in terms of size, weight, power density, manufacturing cost, efficiency, reliability, and noise. Figure 1 is a perspective view of a brushless permanent magnet motor. FIG. 2 is a perspective view of the stator assembly of the brushless permanent magnet motor of FIG. 1. FIG. 3 is a perspective view of a plurality of stator core subassemblies of the stator assembly of FIG. 2. FIG. 4 is a perspective view of the termination assembly of the stator assembly of FIG. 2. FIG. 5 is a perspective view of one stator core subassembly of the stator assembly of FIG. 2. FIG. 6 is a cross-sectional view penetrating the stator core subassembly of FIG. 5. FIG. 7 is a perspective view of the rotor assembly of the brushless permanent magnet motor of FIG. 1. FIG. 8 is a cross-sectional view through the brushless permanent magnet motor of FIG. 1. FIG. 9 is a cross-sectional view through which the brushless permanent magnet motor of FIG. 1 has the rotor assembly and diffuser removed. FIG. 10 is a perspective view of the end cap of the brushless permanent magnet motor of FIG. 1. FIG. 11 is an enlarged cross-sectional view of the inlet end of the brushless permanent magnet motor of FIG. 1. FIG. 12 is a flowchart illustrating a first method for manufacturing a brushless permanent magnet motor. FIG. 13 is a flowchart illustrating a second method for manufacturing a brushless permanent magnet motor. FIG. 14 is a schematic perspective view of a vacuum cleaner with the brushless permanent magnet motor of FIG. 1 integrated. A brushless permanent magnet motor according to the present invention (generally designated as reference numeral 1) is illustrated in FIG. 1, and components of the brushless permanent magnet motor are illustrated in FIG. 2 through 7. Although this specification describes a brushless permanent magnet motor, those skilled in the art will understand that at least some of the teachings disclosed in this specification may also be applied to other types of brushless motors. A brushless permanent magnet motor includes a stator assembly (10), a rotor assembly (12), and a frame (14). The stator assembly (10) is shown separately in FIG. 2 and includes four stator core subassemblies (16) and a terminal assembly (18). The four stator core subassemblies are shown connected in FIG. 3, and the terminal assembly (18) is shown separately in FIG. 4. One individual stator core subassembly (16) is shown in FIG. 5 and FIG. 6, and it will be understood that each stator core subassembly (16) has substantially the same structure. The stator core subassembly (16) comprises a stator core (20), a bobbin (22), and a winding (24) wound on the bobbin (22). The stator core (20) has a back section (26), a first arm (28) and a second arm (30) extending from the back section (26). The stator core (20) generally has a C-shaped form and may also be referred to as a C-core. The first arm (28) and the second arm (30) each include a first section (32, 34) and a second section (36, 38). Each first section (32, 34) extends substantially perpendicularly from the back section (26), and each second section (36, 38) forms an angle of about 28 degrees relative to each first section (32, 34). Each second part (36, 38) is about twice the length of each first part (32, 34). The second portions (36, 38) are inclined inward toward each other, and the back portion (26), the first arm (28), and the second arm (30) collectively define a winding channel (40) in which the winding (24) is located. Considering the relative orientations of the back portion (26), the first arm (28), and the second arm (30), the winding channel (40) has a generally trapezoidal cross-sectional area as shown in FIG. 6. By providing a winding channel (40) that is generally trapezoidal, a winding pattern that achieves a relatively high filling rate of the winding (24) can be obtained, while it has been found that the height of the stator core (20) can be reduced by inclining the second portions (36, 38) of the first arm (28) and the second arm (30) inward toward each other. The stator core (20) includes pole faces (42, 44) disposed at the ends of each second part (36, 38), and the pole faces (42, 44) extend to both sides of each second part (36, 38). The pole faces (42, 44) are spaced apart from each other to define a slot gap (46), and the slot gap (46) defines an entry point into the winding channel (40). The pole faces (42, 44) are asymmetric to provide saliency, and each pole face (42, 44) is curved with a different center of curvature. Due to the asymmetry of the pole faces (42, 44), the distance from each pole face (42, 44) to the centerline B of the slot gap (46) is different. Each polar surface (42, 44) is asymmetric with respect to th