US-12620847-B2 - Stator for AFPM motor and method of manufacturing the same

US12620847B2US 12620847 B2US12620847 B2US 12620847B2US-12620847-B2

Abstract

An embodiment stator for an axial flux permanent magnet (AFPM) motor includes a plurality of stator cores arranged in a circumferential direction, each stator core of the plurality of stator cores including a winding portion on which a coil is wound and end portions of a wedge shape on both sides of the winding portion, and a plurality of core support members, each core support member of the plurality of core support members including a pair of first support portions configured to support the end portions, a second support portion connecting a first end of a first one of the pair of first support portions to a first end of a second one of the pair of first support portions, and a third support portion connecting second ends of the pair of first support portions to each other.

Inventors

Dong Hee Lee
Jae Hyuk Seo
Ji Yeon Kim
Jae Wan Choi

Assignees

KIA CORPORATION
HYUNDAI MOTOR COMPANY

Dates

Publication Date: 20260505
Application Date: 20231121
Priority Date: 20230628

Claims (18)

1 . A stator for an axial flux permanent magnet (AFPM) motor, the stator comprising: a plurality of stator cores arranged in a circumferential direction, each stator core of the plurality of stator cores comprising a winding portion on which a coil is wound and end portions of a wedge shape on both sides of the winding portion; and a plurality of core support members, each core support member of the plurality of core support members comprising a pair of first support portions configured to support the end portions, a second support portion connecting a first end of a first one of the pair of first support portions to a first end of a second one of the pair of first support portions, and a third support portion connecting second ends of the pair of first support portions to each other.
2 . The stator of claim 1 , wherein the second support portion protrudes from the first end of each first support portion of the pair of first support portions in both circumferential directions and has a greater width than a combined width of the pair of first support portions.
3 . The stator of claim 1 , wherein each first support portion of the pair of first support portions is in contact with an inner surface of a corresponding one of the end portions.
4 . The stator of claim 1 , wherein each stator core of the plurality of stator cores further comprises a pair of bobbins mounted on both sides of the winding portion and located on inner surfaces of the end portions, each bobbin of the pair of bobbins comprising an elastic hole disposed in one side thereof.
5 . The stator of claim 4 , wherein, in a state in which each bobbin of the pair of bobbins is supported by the second support portion, the pair of bobbins elastically supports each stator core of the plurality of stator cores as the elastic hole is deformed.
6 . The stator of claim 5 , wherein each bobbin of the pair of bobbins is placed between an inner surface of a corresponding one of the pair of first support portions and the coil.
7 . The stator of claim 1 , wherein the second support portion comprises a first through-hole in a center thereof, and wherein the third support portion comprises a second through-hole in a center thereof.
8 . The stator of claim 1 , wherein the second support portion comprises first grooves defined in both side ends thereof in the circumferential direction.
9 . The stator of claim 1 , wherein the second support portion is in a rounded shape.
10 . The stator of claim 1 , wherein each first support portion of the pair of first support portions further comprises a partition wall protruding in a longitudinal direction to prevent the plurality of stator cores from contacting each other.
11 . A method of manufacturing a stator for an axial flux permanent magnet (AFPM) motor, wherein the stator comprises a plurality of stator cores arranged in a circumferential direction and a plurality of core support members, wherein each stator core of the plurality of stator cores comprises a winding portion on which a coil is wound and end portions of a wedge shape on both sides of the winding portion, and wherein each core support member of the plurality of core support members comprises a pair of first support portions configured to support the end portions, a second support portion connecting a first end of a first one of the pair of first support portions to a first end of a second one of the pair of first support portions, and a third support portion connecting second ends of the pair of first support portions to each other, the method comprising: arranging the plurality of stator cores in a circumferential direction, each of the plurality of stator cores comprising a winding portion on which a coil is wound and on which a bobbin is mounted and end portions disposed on both sides of the winding portion; mounting the plurality of core support members such that each of the core support members is disposed between two adjacent ones of the stator cores arranged in the circumferential direction; and press-fitting a support ring on outer surfaces of the second support portions of the plurality of core support members.
12 . The method of claim 11 , further comprising pressing the second support portions of the plurality of core support members in a direction of center to deform an elastic hole formed in the bobbin before press-fitting the support ring.
13 . The method of claim 11 , wherein the second support portion protrudes from the first end of each first support portion of the pair of first support portions in both circumferential directions and has a greater width than a combined width of the pair of first support portions.
14 . The method of claim 11 , wherein each first support portion of the pair of first support portions is in contact with an inner surface of a corresponding one of the end portions.
15 . The method of claim 11 , wherein the second support portion comprises a first through-hole in a center thereof, and wherein the third support portion comprises a second through-hole in a center thereof.
16 . The method of claim 11 , wherein the second support portion comprises first grooves defined in both side ends thereof in the circumferential direction.
17 . The method of claim 11 , wherein the second support portion is in a rounded shape.
18 . The method of claim 11 , wherein each first support portion of the pair of first support portions further comprises a partition wall protruding in a longitudinal direction to prevent the plurality of stator cores from contacting each other.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of Korean Patent Application No. 10-2023-0083469, filed on Jun. 28, 2023, which application is hereby incorporated herein by reference. TECHNICAL FIELD The present disclosure relates to a stator for an axial flux permanent magnet (AFPM) motor and a method of manufacturing the same. BACKGROUND In general, a motor includes a rotor equipped with a magnet and a stator equipped with a coil, and the rotor is rotated when a voltage is applied to the coil. A motor is classified into two types: an axial flux permanent magnet (AFPM) motor and a radial flux permanent magnet (RFPM) motor. An AFPM motor has a very short axial length compared to an RFPM motor, and thus is very useful in a driving system that requires a motor having a short axial length. In order to secure stator cores, a conventional AFPM motor includes a T-shaped support member mounted between the stator cores and a support ring surrounding the support member to tightly secure the same. However, the conventional structure for securing stator cores has problems in that a space factor is reduced because the T-shaped support member is located between the stator cores and in that it is difficult to cool coils wound on the stator cores because fluid does not flow between the stator cores. Therefore, there is a need to develop novel technology for solving the above problems. The information disclosed in this background section is only for enhancement of understanding of the general background of embodiments of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the related art already known to a person skilled in the art. SUMMARY Accordingly, embodiments of the present disclosure are directed to a stator for an AFPM motor and a method of manufacturing the same that substantially obviate one or more problems due to limitations and disadvantages of the related art. An embodiment of the present disclosure provides a stator for an AFPM motor, which includes a stator core support member having a novel structure for improving a space factor and cooling efficiency while securely supporting stator cores arranged in a circumferential direction, and a method of manufacturing the same. Additional advantages, objects, and features of embodiments of the disclosure will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the disclosure. The objectives and other advantages of embodiments of the disclosure may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings. Various aspects of embodiments of the present disclosure are directed to a stator for an AFPM motor including a plurality of stator cores arranged in a circumferential direction, each including a winding portion on which a coil is wound and end portions of a wedge shape on both sides of the winding portion, and a plurality of core support members, each including a pair of first support portions spaced apart from each other in a longitudinal direction of the winding portion to support the end portions, a second support portion connecting one end of one of the pair of first support portions to one end of the remaining one of the pair of first support portions, and a third support portion connecting the opposite ends of the pair of first support portions to each other. In at least one embodiment of the present disclosure, the second support portion may protrude from one end of each of the pair of first support portions in both circumferential directions and may have a greater width than the pair of first support portions. In at least one embodiment of the present disclosure, each of the pair of first support portions may be in contact with an inner surface of a corresponding one of the end portions. In at least one embodiment of the present disclosure, each of the plurality of stator cores may further include a pair of bobbins mounted on both sides of the winding portion and located on inner surfaces of the end portions, and each of the pair of bobbins may include an elastic hole formed in one side thereof. When each of the pair of bobbins is supported by the second support portion, the pair of bobbins may elastically support each of the plurality of stator cores as the elastic hole is deformed. In at least one embodiment of the present disclosure, each of the pair of bobbins may be mounted between an inner surface of a corresponding one of the pair of first support portions and the coil. In at least one embodiment of the present disclosure, the pair of first support portions may have the same thickness as the pair of bobbins. In at least one embodiment of the present disclosure, the second support portion may include a first through-hole formed in a