An injection molded stator and outer rotor motor

Abstract

The present invention discloses an injection molded stator and an outer rotor motor. The injection molded stator includes a winding, an iron core, a control board, a mounting bracket and a plastic-sealed shell. The winding is wound around the iron core. One end of the mounting bracket is inserted into the inner hole of the iron core. The other end of the mounting bracket cooperates with the control board. The plastic-sealed shell includes a flange cover, an upper fixing cylinder and a lower fixing cylinder. The flange cover is sleeved on the outside of the mounting bracket. The control board is arranged inside the flange cover. The upper end of the upper fixing cylinder is connected to the flange cover as a whole. The lower end of the upper fixing cylinder is sleeved on the upper end of the winding. The upper end of the lower fixing cylinder is sleeved on the lower end of the winding. An outer rotor motor includes the injection molded stator. The control board is arranged inside the plastic-sealed shell to protect the control board and increase its service life. The structure of the mounting bracket is simplified, the functions of the mounting bracket are reduced, and the manufacturing cost and precision requirements are reduced. Thus, the overall quality and service life are improved.

Description

Technical Field

[0001] The invention relates to the technical field of external rotor motors, in particular to an injection-molded stator and an external rotor motor. Background Art

[0002] The DC brushless motors in the household appliance fan and heater industry generally use external rotor motors (such as Figure 1 ), this type of external rotor motor consists of an inner stator part, a rotor part, and a control board part. The winding of the inner stator of the motor is wound on the iron core, and the bearing bracket and the control board are crimped together and then pressed into the inner hole of the iron core to complete the inner stator part. The rotor part of the motor is processed as follows: the magnetic material is pressed into the inner wall of the metal end cover in an annular shape, the small bearing is inserted into one end of the shaft, the large bearing is inserted into the other end of the shaft, the shaft with the bearing is inserted into the middle hole of the bearing bracket, and finally the inner hole of the metal end cover and the shaft are crimped into one. Although the structure is simple, the control board is easily damaged due to long-term exposure to the outside, especially in appliances such as bathroom heaters that are used in humid environments, and the damage is serious.

[0003] The above-mentioned bearing bracket is as follows Figure 2 The bearing bracket is the supporting component of the entire motor, with bearing chambers at both ends. The inner diameters of the two bearing chambers of the bearing bracket have high precision requirements. General metal materials cannot meet the precision requirements through casting. Special materials or an additional lathe finishing process are required to meet the precision requirements. Otherwise, the bearing will cause loud noise, and the high precision requirements will lead to excessively high costs for the entire bearing bracket. Summary of the invention

[0004] The present invention aims at solving the above-mentioned deficiencies in the prior art and provides an injection molded stator and outer rotor motor, in which a control board is arranged inside a plastic package shell to protect the control board and increase its service life; the structure of the mounting bracket is simplified, the functions of the mounting bracket are reduced, and the functions are replaced by other structures, thereby improving the convenience of mounting bracket processing and reducing manufacturing costs and precision requirements; thereby improving the overall quality and service life.

[0005] To achieve the above object, the present invention provides the following technical solutions:

[0006] An injection molded stator comprises a winding, an iron core, a control board, a mounting bracket and a plastic-sealed shell, wherein the winding is wound around the iron core, one end of the mounting bracket is inserted into an inner hole of the iron core, and the other end of the mounting bracket cooperates with the control board, and the plastic-sealed shell comprises a flange cover, an upper fixing cylinder and a lower fixing cylinder, wherein the flange cover is sleeved on the outside of the mounting bracket, and the control board is arranged on the inside of the flange cover, the upper end of the upper fixing cylinder is connected to the flange cover as a whole, the lower end of the upper fixing cylinder is sleeved on the upper end of the winding, and the upper end of the lower fixing cylinder is sleeved on the lower end of the winding.

[0007] Preferably, the mounting bracket is a cylindrical structure, a fixing column is provided on one side of the mounting bracket, an axial hole is provided in the middle of the control panel, a fixing groove is provided on the inner wall of the axial hole, and the fixing groove cooperates with the fixing column.

[0008] Preferably, an external boss is provided on the side wall of the mounting bracket, a locking column is provided on the side of the external boss facing the control panel, and a connecting hole cooperating with the locking column is provided on the control panel.

[0009] An outer rotor motor comprises the injection-molded stator.

[0010] Preferably, a rotating shaft is provided in the middle of the injection-molded stator, and a shell is sleeved on the outside of the injection-molded stator. A permanent magnet is provided on the inner wall of the shell, and the permanent magnet is sleeved on the outside of the iron core.

[0011] Preferably, large bearings are provided between the rotating shaft and the flange cover, and between the lower fixing cylinder and the bearing.

[0012] Preferably, the housing and the rotating shaft are connected as one body via an injection molded disk.

[0013] Preferably, a large bearing is provided between the rotating shaft and the flange cover, a small bearing is provided between the lower fixing cylinder and the bearing, and the housing and the rotating shaft are fixed by crimping.

[0014] Preferably, a large bearing is provided between the flange cover and the rotating shaft, the housing and the rotating shaft are connected as a whole through an injection molded disk, a plastic sleeve is provided on the inner side of the plastic disk and is sleeved on the outside of the rotating shaft, and the plastic sleeve and the plastic disk are an integrated structure.

[0015] Preferably, a small bearing is provided between the rotating shaft and the mounting bracket.

[0016] Compared with the prior art, the present invention has the following beneficial effects:

[0017] The present invention arranges the control board inside the plastic-sealed shell to protect the control board and increase its service life; replaces the existing bearing bracket with an installation bracket, simplifies the structure of the installation bracket, reduces the function of the installation bracket, and replaces the function with other structures, thereby improving the convenience of processing the installation bracket and reducing the manufacturing cost and precision requirements; thereby improving the overall quality and service life. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a schematic diagram of the structure of a brushless DC outer rotor motor in the prior art;

[0019] Figure 2 It is a structural schematic diagram of an existing bearing bracket;

[0020] Figure 3 It is a schematic diagram of the structure of the injection-molded stator;

[0021] Figure 4 It is a structural schematic diagram of the outer rotor motor of Embodiment 1;

[0022] Figure 5 It is a structural schematic diagram of the outer rotor motor of the second embodiment;

[0023] Figure 6 This is a schematic diagram of the structure of the outer rotor motor of Embodiment 3;

[0024] Figure 7 This is a schematic diagram of the structure of the outer rotor motor of Embodiment 4;

[0025] Figure 8 This is a schematic diagram of the structure of the outer rotor motor of Embodiment 5;

[0026] Fig. 9 This is a schematic diagram of the structure of the outer rotor motor of Embodiment 6;

[0027] Fig.10 It is a structural schematic diagram of the mounting bracket;

[0028] Fig.11 This is a schematic diagram of the structure of the control panel.

[0029] In the figure: 1-winding; 2-iron core; 3-inner hole of iron core; 4-bearing bracket; 5-small bearing; 6-housing; 7-rotating shaft; 8-large bearing; 9-control board; 901-fixing groove; 902-shaft hole; 903-connecting hole; 10-bearing chamber; 11-mounting bracket; 1101-fixing column; 1102-external boss; 1103-locking column; 12-plastic sealed shell; 1201-flange cover; 1202-upper fixing cylinder; 1203-lower fixing cylinder; 13-magnet; 14-plastic disc; 1401-plastic sleeve. DETAILED DESCRIPTION

[0030] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0031] like Figure 3-4As shown, an injection molded stator includes a winding 1, an iron core 2, a control board 9, a mounting bracket 11 and a plastic-sealed shell 12. The iron core 2 is made of stacked steel sheets, the winding 1 is wound around the iron core 2, one end of the mounting bracket 11 is inserted into the inner hole 3 of the iron core, and the other end of the mounting bracket 11 cooperates with the control board 9. The plastic-sealed shell 12 includes a flange cover 1201, an upper fixed cylinder 1202 and a lower fixed cylinder 1203. The flange cover 1201 is sleeved on the outside of the mounting bracket 11, and the control board 9 is arranged inside the flange cover 1201. The upper end of the upper fixed cylinder 1202 is connected to the flange cover 1201 as a whole, the lower end of the upper fixed cylinder 1202 is sleeved on the upper end of the winding 1, and the upper end of the lower fixed cylinder 1203 is sleeved on the lower end of the winding 1.

[0032] like Figure 10-11 As shown, the mounting bracket 11 is a cylindrical structure, and a fixing column 1101 is provided on one side of the mounting bracket 11, and the number is 1-4. The middle part of the control board 9 is provided with an axial hole 902, and the inner wall of the axial hole 902 is provided with a fixing groove 901, and the number of the fixing grooves 901 is 3, and the fixing grooves 901 cooperate with the fixing column 1101. The inner hole size of the control board 9 is smaller than the outer diameter of the mounting bracket 11, and one end of the mounting bracket is pressed into the inner hole 3 of the iron core, and the control board 9 is inserted from the other end of the mounting bracket 11 and placed on one side of the mounting bracket 3. The fixing groove 901 of the control board 9 and the three fixing columns 1101 of the mounting bracket are just locked and positioned to prevent the control board from radially moving relative to the mounting bracket.

[0033] Furthermore, an outer boss 1102 is provided on the side wall of the mounting bracket 11, and a locking column 1103 is provided on the side of the outer boss 1102 facing the control board 9, and a connecting hole 903 cooperating with the locking column 1103 is provided on the control board 9. The control board 9 is fixed to the mounting bracket 11 by riveting the outer boss 1102 to prevent the control board 9 from axially moving relative to the mounting bracket 11. Alternatively, the connecting hole 903 on the control board 9 is eliminated, and an ejector pin is directly provided on the outer shell of the mold to hold the locking column 1103, so that the mounting bracket 11 can be axially fixed.

[0034] The material of the mounting surface may be metal or hard plastic.

[0035] The winding 1, the iron core 2, the control board 9 and the mounting bracket 11 are put into the injection mold, and the winding 1, the iron core 2, the control board 9 and the mounting bracket 11 are injection-molded into one piece with a polymer plastic molding compound. Two bearing chambers are formed at both ends of the plastic-encapsulated stator with the plastic molding compound to form a plastic-encapsulated stator.

[0036] Embodiment 1,

[0037] like Figure 5 As shown, an outer rotor motor includes the injection molded stator.

[0038] A rotating shaft 7 is provided in the middle of the injection molded stator, and a shell 6 is sleeved on the outside of the injection molded stator. A permanent magnet 13 is provided on the inner wall of the shell 6 , and the permanent magnet 13 is sleeved on the outside of the iron core 2 .

[0039] Processing process of the rotor: the permanent magnet 13 is pressed into the metal housing 6, the shaft 7 and the housing 6 are connected and injection-molded into one piece using plastic (plastic disk 14), and the rotor is magnetized.

[0040] The motor assembly process: the rotor is inserted into the stator, the shaft 7 is extended from the end face of the stator, and the bearings are assembled at both ends of the stator.

[0041] Embodiment 2:

[0042] like Figure 6 As shown, the shaft-out direction of this embodiment is opposite to that of the second embodiment, and the rest of the structures are the same.

[0043] Embodiment 3,

[0044] An outer rotor motor comprises the injection-molded stator.

[0045] like Figure 6 As shown, a rotating shaft 7 is provided in the middle of the injection molded stator, and a shell 6 is sleeved on the outside of the injection molded stator. A permanent magnet 13 is provided on the inner wall of the shell 6, and the permanent magnet 13 is sleeved on the outside of the iron core 2.

[0046] Large bearings 8 are provided between the rotating shaft 7 and the flange cover 1201 and between the lower fixed cylinder 1203 and the bearing.

[0047] The housing 6 and the rotating shaft 7 are connected as a whole via an injection molded disc.

[0048] Embodiment 4:

[0049] An outer rotor motor comprises the injection-molded stator.

[0050] like Figure 6 As shown, a rotating shaft 7 is provided in the middle of the injection molded stator, and a shell 6 is sleeved on the outside of the injection molded stator. A permanent magnet 13 is provided on the inner wall of the shell 6, and the permanent magnet 13 is sleeved on the outside of the iron core 2.

[0051] like Figure 7 As shown, a large bearing 8 is provided between the rotating shaft 7 and the flange cover 1201, a small bearing 5 is provided between the lower fixing cylinder 1203 and the bearing, and the housing 6 and the rotating shaft 7 are fixed by crimping.

[0052] Embodiment 5,

[0053] An outer rotor motor comprises the injection-molded stator.

[0054] like Figure 6 As shown, a rotating shaft 7 is provided in the middle of the injection molded stator, and a shell 6 is sleeved on the outside of the injection molded stator. A permanent magnet 13 is provided on the inner wall of the shell 6, and the permanent magnet 13 is sleeved on the outside of the iron core 2.

[0055] like Figure 8 As shown, a large bearing 8 is provided between the flange cover 1201 and the rotating shaft 7, the housing 6 and the rotating shaft 7 are connected as a whole through an injection molded disk, and a plastic disk 1401 is provided on the inner side of the plastic disk 14 and is sleeved on the outside of the rotating shaft 7, and the plastic disk 1401 and the plastic disk 14 are an integrated structure.

[0056] Embodiment 6

[0057] like Fig. 9 As shown, in this embodiment, based on the fifth embodiment, a small bearing 5 is provided between the rotating shaft 7 and the mounting.

[0058] Obviously, those skilled in the art can make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include these modifications and variations.

Claims

1. An injection molded stator, characterized in that: It includes a winding, an iron core, a control board, a mounting bracket and a plastic-sealed shell, wherein the winding is wound around the iron core, one end of the mounting bracket is inserted into the inner hole of the iron core, and the other end of the mounting bracket cooperates with the control board, and the plastic-sealed shell includes a flange cover, an upper fixing cylinder and a lower fixing cylinder, wherein the flange cover is sleeved on the outside of the mounting bracket, and the control board is arranged inside the flange cover, the upper end of the upper fixing cylinder is connected to the flange cover as a whole, the lower end of the upper fixing cylinder is sleeved on the upper end of the winding, and the upper end of the lower fixing cylinder is sleeved on the lower end of the winding; The mounting bracket is a cylindrical structure, a fixing column is provided on one side of the mounting bracket, an axial hole is provided in the middle of the control panel, a fixing groove is provided on the inner wall of the axial hole, and the fixing groove cooperates with the fixing column; An external boss is arranged on the side wall of the mounting bracket, a locking column is arranged on the side of the external boss facing the control panel, and a connecting hole cooperating with the locking column is arranged on the control panel.

2. An outer rotor motor, characterized in that: Comprising the injection molded stator as claimed in claim 1.

3. An outer rotor motor as claimed in claim 2, characterized in that: A rotating shaft is arranged in the middle of the injection-molded stator, and a shell is sheathed on the outside of the injection-molded stator. A permanent magnet is arranged on the inner wall of the shell, and the permanent magnet is sheathed on the outside of the iron core.

4. An outer rotor motor as claimed in claim 3, characterized in that: Large bearings are arranged between the rotating shaft and the flange cover, and between the lower fixing cylinder and the bearing.

5. An outer rotor motor as claimed in claim 4, characterized in that: The shell and the rotating shaft are connected as a whole through a plastic disk.

6. An outer rotor motor as claimed in claim 4, characterized in that: A large bearing is arranged between the rotating shaft and the flange cover, a small bearing is arranged between the lower fixing cylinder and the bearing, and the housing and the rotating shaft are fixed by crimping.

7. An outer rotor motor as claimed in claim 3, characterized in that: A large bearing is arranged between the flange cover and the rotating shaft, the housing and the rotating shaft are connected as a whole through a plastic disk, a plastic sleeve which is sleeved on the outside of the rotating shaft is arranged on the inner side of the plastic disk, and the plastic sleeve and the plastic disk are in an integrated structure.

8. An outer rotor motor as claimed in claim 7, characterized in that: A small bearing is arranged between the rotating shaft and the mounting bracket.

Images