Stator support structure of brushless blower motor and processing method thereof

Abstract

This invention provides a stator support structure and its processing method for a brushless blower motor, belonging to the field of automotive parts manufacturing technology. The invention uses aluminum sheet stamping to obtain a base plate with several support columns. Simultaneously, a plastic connector with several snap-fit ​​columns is injection molded on the base plate, located on one side extending from the support columns. The support columns achieve radial positioning and support of the stator structure, realizing high-precision coaxial positioning between the stator structure and the motor housing. The snap-fit ​​columns axially lock the stator structure, eliminating the problems of needing to tighten nuts and the tendency for loosening and accumulated errors associated with existing bolt connections. Furthermore, the lower-density plastic connector replaces the original aluminum and other metal materials, resulting in lighter weight. The use of a stamping-then-injection molding process for the base plate and plastic connector improves processing efficiency, avoids casting waste, increases material utilization, lowers manufacturing costs, and improves the motor's assembly accuracy and quiet operation.

Description

Technical Field

[0001] This invention relates to the field of automotive parts manufacturing technology, specifically to a stator support structure for a brushless blower motor and its processing method. Background Technology

[0002] In automotive air conditioning systems, brushless blower motors are widely used as power sources and are a key structure for refrigerant delivery, with a broad market prospect. Therefore, improving the performance of brushless blower motors and reducing manufacturing costs are directions that the industry needs to continuously research.

[0003] Currently, commercially available brushless blower motors typically consist of a stator formed by coil assemblies and a rotor formed by permanent magnet assemblies. Power output is achieved by the rotor moving in the magnetic field generated by the stator. For example, the motor and its stator structure disclosed in patent CN105846559A include a support base, a stator structure fitted onto the support base, and a rotor structure interacting with the stator structure, the rotor structure surrounding the stator structure. In this case, a hollow sleeve protrudes axially upward from the center of the support base to support the rotor's rotation. The sleeve's outer wall at its top protrudes outward to form a protrusion for circumferential positioning with the stator structure. Additionally, the support base also has two fixed posts and two positioning posts, arranged around the sleeve. Along the circumference of the sleeve, the positioning posts and fixed posts are alternately distributed. Each fixed post contains a fixing hole, which can be a round hole or a screw hole, for fixed connection with the stator structure. Therefore, existing stators typically use sleeves, fixing posts, and positioning posts on a support base to secure the stator structure. Screws pass through the stator structure and connect to fixing holes to achieve axial positioning of the stator on the support base. Sleeves and protrusions provide radial and circumferential positioning of the stator structure, thus ensuring stable installation. While this structure achieves stable installation of the stator on the support base, existing support bases are usually made of aluminum, integrally die-cast (i.e., all-die-cast aluminum support bases), resulting in high raw material costs and heavy weight. Furthermore, the need for bolts and other structural components to install the stator structure onto the support base increases procurement and management costs, makes assembly cumbersome, and introduces the risk of loosening and cumulative assembly errors, thus affecting product performance. Summary of the Invention

[0004] To address the aforementioned problems in existing technologies, this paper aims to provide a stator support structure for a brushless blower motor and its processing method. A stamped aluminum plate is used as the base plate, and support columns are simultaneously stamped to form support columns. Plastic snap-fit ​​columns are then injection molded onto the base plate to snap onto the stator structure. The stamping process not only improves efficiency but also avoids casting waste, increasing material utilization. Furthermore, by using plastic snap-fit ​​columns to snap onto the stator assembly, bolts and other structural components are eliminated; installation is simply a press-fit process. Fewer parts result in efficient and convenient assembly, reducing procurement and management costs. Additionally, low-density plastic can replace some high-density metal materials, reducing manufacturing costs and weight. The injection-molded plastic can also fill weak areas of the stamped aluminum plate, improving the structural strength of the support structure and extending its service life. Moreover, it eliminates the problems of loosening and accumulated errors caused by bolts and other structural installations, improving overall performance.

[0005] The specific technical solution is as follows: A stator support structure for a brushless blower motor is characterized by comprising: a base plate and a plastic connector. The base plate is a stamped aluminum plate with a central hole in the middle. During the stamping process of the base plate, several support columns extending to one side are simultaneously stamped at the edge of the central hole. A plastic connector is injection molded on the base plate on the side where the support columns extend. The plastic connector is located on the inner side of the base plate and at the part that supports the stator structure. The plastic connector is provided with several snap-fit ​​columns extending in the same direction as the support columns. A snap-fit ​​hook is provided at the end of the snap-fit ​​column away from the base plate. The stator structure is provided with snap-fit ​​holes corresponding to the snap-fit ​​columns.

[0006] The stator support structure of the brushless blower motor described above is provided with several positioning holes, and the positioning holes correspond one-to-one with several support columns.

[0007] In the stator support structure of the aforementioned brushless blower motor, a plastic connector is located at one end of the substrate, extending from the central hole to the other side of the substrate and wrapping around the edge of the central hole.

[0008] In the stator support structure of the brushless blower motor described above, a plurality of recessed holes are provided on the substrate and located beside the central hole. During the injection molding of the plastic connector, the material of the plastic connector fills each recessed hole, and the recessed hole penetrates the substrate.

[0009] In the stator support structure of the aforementioned brushless blower motor, the width of the locking hole on the stator structure is greater than the thickness of the locking post.

[0010] In the stator support structure of the brushless blower motor described above, auxiliary mounting posts are provided on both sides of each snap-fit ​​post on the plastic connector, with a gap between the auxiliary mounting posts and the snap-fit ​​posts, and auxiliary positioning grooves are provided on both sides of the snap-fit ​​hole, with the width of the auxiliary positioning grooves being the same as the thickness of the auxiliary mounting posts.

[0011] The stator support structure of the brushless blower motor described above, wherein the slots on the stator structure and located at the end of each auxiliary mounting slot near the base plate are arranged in an flared manner.

[0012] A method for processing the stator support structure of a brushless blower motor, used to process the stator support structure of the aforementioned brushless blower motor, includes the following steps: Step S1, substrate stamping; An aluminum plate is placed into a stamping die for a substrate, and the aluminum plate is stamped by a stamping head to obtain a substrate with several support pillars, which is then collected for later use. Step S2: Injection molding of the plastic connector; The substrate with several support columns is placed into the injection mold of the plastic connector and fixed. Plastic is placed into the injection mold and cooled and solidified to form a plastic connector with several snap-fit ​​columns on the substrate with several support columns. The connector is collected for later use, thus completing the processing of the stator support structure of the brushless blower motor.

[0013] The positive effects of the above technical solution are: The stator support structure and its processing method of the aforementioned brushless blower motor use a stamped aluminum plate as the base plate, and simultaneously stamping to form several support columns. This improves processing efficiency, avoids casting waste, and achieves high-precision coaxial positioning of the stator structure, ensuring uniform air gap and suppressing electromagnetic vibration and howling caused by eccentricity. Simultaneously, a plastic connector with several snap-fit ​​columns is injection molded on the base plate and on one side of the support column extension. The snap-fit ​​columns are inserted into the snap holes of the stator structure to achieve a one-click connection, facilitating assembly. This eliminates the need for axial fixation using bolts or other structural components, avoiding the problems of loose nuts and accumulated errors associated with bolt connections. This achieves axial locking and anti-loosening of the stator structure, improving assembly accuracy. Furthermore, the damping and low-density properties of plastic absorb high-frequency vibrations and reduce weight. Additionally, it strengthens weak areas on the base plate, extending motor life, and eliminates bolt procurement and management costs, reducing manufacturing costs. Attached Figure Description

[0014] Figure 1 This is a structural diagram of an embodiment of the stator support structure of a brushless blower motor according to the present invention; Figure 2 An exploded view of an embodiment of the stator support structure of a brushless blower motor according to the present invention; Figure 3 This is a flowchart illustrating a method for processing the stator support structure of a brushless blower motor according to the present invention.

[0015] In the attached diagram: 1. Substrate; 11. Center hole; 12. Support post; 13. Embedded hole; 2. Plastic connector; 21. Snap-on post; 22. Auxiliary mounting post; 211. Hook; 3. Stator structure; 31. Snap-on hole; 32. Positioning hole; 311. Auxiliary positioning groove. Detailed Implementation

[0016] To make the technical means, creative features, objectives, and effects of this invention easier to understand, the following embodiments are provided in conjunction with the appendix. Figure 1 To be continued Figure 3 The technical solutions provided by this invention are described in detail, but the following content is not intended to limit this invention.

[0017] Figure 1 This is a structural diagram of an embodiment of the stator support structure of a brushless blower motor according to the present invention; Figure 2 This is an exploded view of an embodiment of the stator support structure of a brushless blower motor according to the present invention. Figure 1 and Figure 2 As shown, the stator support structure of the brushless blower motor provided in this embodiment includes: a base plate 1 and a plastic connector 2, which are used to install, fix and support the stator structure 3.

[0018] Specifically, substrate 1 is a stamped aluminum plate, which is manufactured using a stamping process. Compared with the traditional die-casting process, the process is simpler and the processing efficiency is higher. It also avoids the generation of casting waste, improves the utilization rate of materials, and avoids the waste of resources. In addition, a central hole 11 is provided in the middle of the substrate 1 to facilitate the installation and rotation of the rotor structure's shaft. During the stamping process of the substrate 1, several support columns 12 extending to one side are simultaneously stamped at the edge of the central hole 11. The support columns 12, which are integrally stamped, improve the utilization rate of the stamping material. They can also serve as the radial positioning and support structure for the stator structure 3 in the later stage. This ensures the high-precision coaxial positioning and installation of the stator structure 3 with the housing, ensuring that the air gap of the motor is uniform and stable, and suppressing usage defects such as electromagnetic vibration and howling caused by eccentricity. Furthermore, a plastic connector 2 is injection molded on the substrate 1 and on the side where the support column 12 extends. This achieves integral injection molding of the plastic connector 2 on the substrate 1, improving the structural reliability and stability of the plastic connector 2 after it is connected on the substrate 1. This also ensures that the plastic connector 2 can tightly lock the stator structure 3 to prevent loosening. At this time, the plastic connector 2 is disposed on the inner side of the substrate 1 and located on the part that supports the stator structure 3, so that the plastic connector 2 can fill the weak area of ​​the substrate 1 and generate a reinforcing rib effect on the substrate 1, thereby improving the overall rigidity and deformation resistance of the support structure, resulting in higher structural strength and extending the service life of the motor. In addition, the plastic connector 2 is provided with several snap-fit ​​posts 21 extending in the same direction as the support post 12, and the end of the snap-fit ​​post 21 facing away from the base plate 1 is provided with a hook 211. The stator structure 3 is provided with snap-fit ​​holes 31 corresponding to the snap-fit ​​posts 21. During installation, the snap-fit ​​post 21 is inserted and passes through the snap-fit ​​hole 31, and the hook 211 hooks the edge of the hole 31, so that the stator structure 3 is snapped and installed on the base plate 1 by the snap-fit ​​post 21. Compared with the existing structure that uses bolts and other structural components to install the stator structure 3 on the support base, there is no need to use bolts and other structural components, saving the process of manually tightening nuts. Only pressing is required for installation, realizing one-click positioning and assembly. The assembly process is simpler and the assembly efficiency is higher. It eliminates the cost of bolt procurement and management. At the same time, it can also prevent the stator structure 3 from loosening due to the loosening of nuts during use, improve the installation stability and reliability, and also eliminate the cumulative error caused by bolt connection, improve the assembly accuracy, ensure product quality, and improve the quietness of motor operation. In addition, by using plastic connector 2 as the connection structure for mounting the stator structure 3 on the base plate 1, the original structure uses high-density metal materials such as aluminum instead of low-density plastic, resulting in a lighter weight and thus reducing the overall weight of the motor. At the same time, the damping characteristics of plastic can be used to absorb high-frequency vibrations during motor operation, further improving the performance of the motor.

[0019] More specifically, the stator structure 3 is provided with several positioning holes 32, and each positioning hole 32 corresponds one-to-one with a number of support columns 12. This allows the stator structure 3 to be radially positioned and supported by inserting the support columns 12 into the positioning holes 32 when it is mounted on the base plate 1. Since the support columns 12 are stamped synchronously with the base plate 1 and are made of the same aluminum metal as the base plate 1, they have high rigidity. This ensures that after the stator structure 3 is mounted on the base plate 1 and subsequently installed in the motor housing, it can achieve high-precision coaxial positioning with the housing, ensuring uniform air gap in the motor. This effectively suppresses electromagnetic vibration and howling caused by eccentricity, improving the performance of the motor. Preferably, the positioning holes 32 are located on the core of the rubber-coated iron core of the stator structure 3. The structural strength of the iron core itself is used to maintain the stability of the positioning holes 32, thereby improving the installation accuracy and stability of the stator structure 3 after it is installed and positioned through the positioning holes 32.

[0020] More specifically, the plastic connector 2 extends from one end of the substrate 1 into the center hole 11 to the other side of the substrate 1 and wraps around the edge of the center hole 11. That is, the plastic connector 2 wraps around both ends of the center hole 11 of the substrate 1 in a reverse wrapping manner, so that the plastic connector 2 can form an approximate slot structure to engage with the center hole 11 of the substrate 1. This improves the connection strength between the two after the plastic connector 2 is injected onto the substrate 1, ensuring that the stator structure 3, which is positioned and installed by the plastic connector 2, can be more stable and reliable after installation.

[0021] More specifically, a plurality of recessed holes 13 are formed on the substrate 1 and located beside the central hole 11. During the injection molding of the plastic connector 2, the material of the plastic connector 2 fills each recessed hole 13. That is, the material flowing into the recessed hole 13 forms a limiting connection structure, which further improves the connection strength between the two and prevents relative rotation, thereby improving the connection stability. Preferably, the recessed holes 13 penetrate the substrate 1, so that the recessed holes 13 on the substrate 1 are a through-hole structure. This allows the two parts of the plastic connector 2 to be connected by the material filled in the recessed holes 13 when the plastic connector 2 wraps around the two ends of the central hole 11 in reverse, forming an integral structure. This further improves the limiting ability and prevents the plastic connector 2 from falling off the substrate 1, resulting in higher structural strength.

[0022] More specifically, the width of the locking hole 31 on the stator structure 3 is greater than the thickness of the locking post 21, so that when the locking post 21 is inserted into the locking hole 31, the locking post 21 has room for deformation. That is, the locking post 21 first deforms and tilts, so that the hook 211 can pass through the locking hole 31. After the hook 211 has completely passed through the locking hole 31, the locking post 21 rebounds in the opposite direction, so that the hook 211 can hook the edge of the opening of the locking hole 31. That is, the axial end face of the stator structure 3 is hooked by the hook 211, thereby stably installing the stator structure 3 on the base plate 1. Moreover, during installation, only pressing the stator structure 3 towards the base plate 1 is required to achieve installation, which meets the requirements of one-click snap-fit ​​installation.

[0023] More specifically, auxiliary mounting posts 22 are provided on both sides of each snap-fit ​​post 21 on the plastic connector 2. A gap is provided between the auxiliary mounting posts 22 and the snap-fit ​​posts 21, allowing them to operate relatively independently and reducing mutual interference during installation. At this time, auxiliary positioning grooves 311 are provided on both sides of the snap-fit ​​hole 31. The width of the auxiliary positioning grooves 311 is the same as the thickness of the auxiliary mounting posts 22. This allows the stator structure 3 to be initially positioned by inserting the auxiliary mounting posts 22 into the auxiliary mounting grooves before the snap-fit ​​posts 21 are fully engaged when installing the stator structure 3 onto the base via the plastic connector 2. This ensures the installation accuracy of the stator structure 3, allowing the stator structure 3 to be positioned and its end-limiting clamping to be achieved through the auxiliary mounting posts 22 and the snap-fit ​​posts 21 respectively. This avoids the problem of the snap-fit ​​posts 21 needing elastic deformation affecting the installation accuracy of the stator structure 3 during installation, resulting in a more rational structural design.

[0024] More specifically, the slots on the stator structure 3, located at the end of each auxiliary mounting slot near the base plate 1, are all arranged in a flared manner. Preferably, the flared arrangement of the slots is achieved by arranging the slot walls of the auxiliary mounting slots in an inclined manner, so that when the auxiliary mounting post 22 is inserted into the auxiliary mounting slot, it can be guided by the flared part of the auxiliary mounting slot, ensuring that the auxiliary mounting post 22 can be accurately and quickly inserted into the auxiliary mounting slot, which facilitates product assembly.

[0025] In addition, this embodiment also provides a method for processing the stator support structure of a brushless blower motor, which is used to process the stator support structure of the brushless blower motor described above. Figure 3 This is a flowchart illustrating a processing method for the stator support structure of a brushless blower motor according to the present invention, as shown below. Figure 3 As shown, a method for fabricating a stator support structure for a brushless blower motor includes the following steps: Step S1, substrate stamping; An aluminum plate is placed into a stamping die of substrate 1, and the aluminum plate is stamped by a stamping head to obtain substrate 1 with several support pillars 12. This achieves one-time stamping forming of substrate 1 and its support pillars 12, making processing more convenient and efficient compared to the traditional die-casting process. It also avoids casting waste and improves material utilization. After obtaining substrate 1 with several support pillars 12, it is collected for later use. Step S2: Injection molding of the plastic connector; The substrate 1 with several support columns 12 is placed into the injection mold of the plastic connector 2 and fixed. Plastic is placed into the injection mold and cooled and solidified to form a plastic connector 2 with several snap-fit ​​columns 21 on the substrate 1 with several support columns 12. This realizes the integral injection molding of several snap-fit ​​columns 21 and the injection molding of the plastic connector 2 on the substrate 1. This not only improves the connection strength between the two, but also makes the stator structure 3 installed by the snap-fit ​​columns 21 more stable and reliable after installation. It also realizes the snap-fit ​​installation of the stator structure 3, eliminating the need for bolts and other structural parts and the tightening of nuts, further reducing manufacturing costs and improving processing efficiency. After obtaining the substrate 1 with the plastic connector 2, it is collected and stored for later use, waiting for the overall assembly of the motor, thus completing the processing of the stator support structure of the brushless blower motor.

[0026] The stator support structure and its processing method for the brushless blower motor provided in this embodiment include a base plate 1 and a plastic connector 2. The base plate 1, with several support columns 12, is obtained by stamping an aluminum plate. Simultaneously, a plastic connector 2 is injection molded on the base plate 1, located on one side extending from the support columns 12. The plastic connector 2 has several snap-fit ​​columns 21, allowing for radial positioning and support of the stator structure 3 during installation via the support columns 12. This achieves high-precision coaxial positioning of the stator structure 3 and the motor housing, ensuring uniform air gap and suppressing electromagnetic vibration and whistling caused by eccentricity. Furthermore, the snap-fit ​​columns 21 enable... The axial locking of the stator structure 3 eliminates the problems of bolts and other structural components, nuts, loosening, and cumulative errors that are common with existing bolted connections. This improves assembly efficiency, reduces manufacturing costs, and makes the system more stable, reliable, and accurate. In addition, the original aluminum and other metal materials are replaced with lower-density plastic connectors 2, resulting in lighter weight. Furthermore, the processing of the base plate 1 and plastic connectors 2 is achieved through a stamping and injection molding process, which improves processing efficiency, avoids casting waste, increases material utilization, reduces manufacturing costs, and enhances the assembly accuracy and quiet operation of the motor.

[0027] The above are merely preferred embodiments of the present invention and are not intended to limit the implementation methods and protection scope of the present invention. Those skilled in the art should recognize that any equivalent substitutions and obvious changes made based on the description and illustrations of the present invention should be included within the protection scope of the present invention.

Claims

1. A stator support structure for a brushless blower motor, characterized by, include: The substrate is a stamped aluminum plate with a central hole in the middle. During the stamping process, several support columns extending to one side are simultaneously stamped along the edge of the central hole. The plastic connector is injection molded on the substrate on the side where the support columns extend. The plastic connector is located on the inner side of the substrate and on the part that supports the stator structure. The plastic connector has several snap-fit ​​columns extending in the same direction as the support columns, and the end of the snap-fit ​​column facing away from the substrate has a snap hook. The stator structure has snap holes corresponding to the snap-fit ​​columns.

2. The stator support structure of a brushless blowing motor according to claim 1, characterized in that, The stator structure is also provided with a number of positioning holes, and the number of positioning holes corresponds one-to-one with the number of support columns.

3. The stator support structure of a brushless blowing motor according to claim 1, characterized by The plastic connector is located at one end of the substrate, extends from the central hole to the other side of the substrate, and wraps around the edge of the central hole.

4. The stator support structure of a brushless blow motor according to claim 3, characterized by A plurality of recessed holes are provided on the substrate and located beside the central hole. During the injection molding of the plastic connector, the material of the plastic connector fills each of the recessed holes, and the recessed holes penetrate the substrate.

5. The stator support structure of a brushless blowing motor according to claim 1, characterized by The width of the locking hole on the stator structure is greater than the thickness of the locking post.

6. A stator support structure for a brushless blow motor according to claim 5, wherein The plastic connector is provided with auxiliary mounting posts on both sides of each of the buckle posts. There is a gap between the auxiliary mounting posts and the buckle posts. Auxiliary positioning grooves are provided on both sides of the buckle hole. The width of the auxiliary positioning grooves is the same as the thickness of the auxiliary mounting posts.

7. A stator support structure for a brushless blow motor according to claim 6, wherein The slots on the stator structure, located at the end of each auxiliary mounting slot closest to the substrate, are all arranged in a flared configuration.

8. A method of processing a stator support structure of a brushless blower motor, for processing the stator support structure of the brushless blower motor according to any one of claims 1 to 6, characterized by, It includes the following steps: Step S1, substrate stamping; An aluminum plate is placed into the stamping die of the substrate, and the aluminum plate is stamped by a stamping head to obtain the substrate with several support columns, which are then collected for later use. Step S2: Injection molding of the plastic connector; The substrate with several support columns is placed into the injection mold of the plastic connector and fixed. Plastic is placed into the injection mold and cooled and solidified to form the plastic connector with several snap-fit ​​columns on the substrate with several support columns. The connector is collected for later use, thus completing the processing of the stator support structure of the brushless blower motor.

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