Techniques for motor component sub-micron radial alignment and airflow management to extend motor life

Abstract

This disclosure generally relates to techniques for radial alignment of motor components relative to each other to achieve a motor with rotor bores having submicron end-to-end misalignment. In an embodiment, a rotor bore alignment tool is disclosed herein, which can be inserted between motor components, and more specifically, between orifices / through holes defined by each motor component, such as housing sections and stator assemblies. The rotor bore alignment tool includes extendable members that can selectively transform to an extended position such that each motor component is radially aligned, the motor components being then securely joined in a so-called “stack” to form a motor. For example, once the motor components are joined together, the resulting motor includes a rotor shaft extending from end to end, preferably including a submicron misalignment of less than 10 micrometers, and more preferably less than or equal to 5 micrometers.

Description

[0001] Cross-referencing related applications

[0002] This application claims the benefit of U.S. Provisional Application No. 62 / 944,068, filed December 5, 2019, which is incorporated herein by reference in its entirety. Technical Field

[0003] This specification generally relates to electric motors, and more specifically, to techniques for submicron radial alignment of motor components, and to diffuser devices used in electric motors to split airflow to generate one or more air jets to cool core motor components such as windings and rotor assemblies. Background Technology

[0004] Electric motors are widely used in consumer and industrial applications. A variety of electric motors are available, and they generally fall into one of two broad types: brushed and brushless.

[0005] For example, a brushed DC motor has permanent magnets on the outside and a spin armature inside. The permanent magnets fixed on the outside are called the stator. The rotating armature that includes the electromagnets is called the rotor. In a brushed DC motor, the rotor spins 180 degrees when current flows to the armature. To maintain rotation, the magnetic poles of the electromagnets must flip. As the rotor rotates, the brushes come into contact with the stator, causing the magnetic field to flip and allowing the rotor to spin a full 360 degrees.

[0006] On the other hand, brushless DC motors do not include brushes and use DC current. Brushless DC motors essentially rotate from the inside out, thus eliminating the need for brushes to rotate the electromagnetic field. For example, in a brushless DC motor, permanent magnets are on the rotor, and electromagnets are on the stator. The circuit can then charge the electromagnets in the stator to make the rotor rotate a full 360 degrees.

[0007] In either case, radial alignment of the rotor within the motor can significantly impact motor performance and reliability. For example, angular and / or radial misalignment of the rotor shaft can significantly affect the motor's nominal power / torque, introduce acoustic noise (e.g., via vibration), and ultimately lead to premature component failure based on, for example, asymmetrical loads along the associated rotor shaft. Summary of the Invention Attached Figure Description

[0008] The accompanying drawings are intended to illustrate various examples of the articles, methods and apparatus taught in this specification, and are not intended to limit the scope of the teachings in any way.

[0009] Figure 1 An example electric motor according to an embodiment of the present disclosure is shown.

[0010] Figure 2An embodiment according to this disclosure is shown. Figure 1 A bottom view of the electric motor.

[0011] Figure 3 A partially disassembled embodiment according to this disclosure is shown. Figure 1 The electric motor.

[0012] Figure 4 An example is shown. Figure 1 A cross-sectional view of the electric motor.

[0013] Figure 5 The radial alignment stage during manufacturing, according to an embodiment, is shown. Figure 1 Another cross-sectional view of the electric motor.

[0014] Figure 6 The following is illustrated according to an embodiment: after the radial alignment stage of manufacturing is performed. Figure 1 Another cross-sectional view of the electric motor.

[0015] Figure 7 A rotor assembly based on the stepped features of the rotor assembly, according to an embodiment of the present disclosure, is shown, which is coupled to and radially aligned with the associated fan / impeller.

[0016] Figure 8 The diagram illustrates the process before insertion into the rotor bore of an electric motor, according to an embodiment of the present disclosure. Figure 7 Rotor assembly.

[0017] Figure 9 The following is shown after insertion into the rotor hole of the electric motor according to an embodiment. Figure 7 Rotor assembly.

[0018] Figure 10A An example lock nut according to an embodiment is shown.

[0019] Figure 10B An example is shown. Figure 1 Another cross-sectional view of the electric motor.

[0020] Figure 11 A perspective view is shown of a diffuser suitable for use in an electric motor according to this disclosure.

[0021] Figure 12 An example is shown. Figure 11 Side view of the diffuser.

[0022] Figure 13 An example is shown. Figure 11 A bottom view of the diffuser.

[0023] Figure 14An example shield is shown for use in an electric motor according to this disclosure.

[0024] Figure 15 An example is shown. Figure 14 A cross-sectional view of an example shield.

[0025] Figure 16 A perspective view of another example diffuser suitable for use in an electric motor according to this disclosure is shown.

[0026] Figure 17 It shows Figure 16 Side view of the diffuser.

[0027] Figure 18 It shows Figure 16 Another perspective view of the diffuser.

[0028] Figure 19 Another example shield is shown for use in an electric motor according to this disclosure.

[0029] Figure 20 An example is shown. Figure 19 A cross-sectional view of an example shield.

[0030] Figure 21 An example is shown. Figure 1 A cross-sectional view of the electric motor.

[0031] Figure 22A Another example shield is shown for use in an electric motor according to this disclosure.

[0032] Figure 22B An example is shown. Figure 22A The cross-section of the protective shield.

[0033] Figure 22C The following illustrations show suitable applications for use according to embodiments. Figure 22A The sealing insertion device in the protective cover.

[0034] Figure 23A Another example electric motor according to this disclosure is shown.

[0035] Figure 23B It shows Figure 23A Side view of the electric motor.

[0036] Figure 23C An embodiment according to this disclosure is shown. Figure 23B A cross-sectional view of the motor taken along line CC. Detailed Implementation

[0037] As discussed above, the radial alignment of the rotor shaft within a motor significantly impacts motor performance and reliability. Motors such as brushless DC (BLDC) motors can be formed from multiple parts / segments sandwiched together in a stacked arrangement. For example, some motors include a housing portion coupled to a stator assembly housed therebetween. Both the housing portion and the stator assembly may each include orifices / through-holes aligned to collectively provide the rotor bore. However, when each component of the motor is coupled together, varying amounts of misalignment are introduced. This misalignment eventually worsens as each component introduces additional misalignment, resulting in an end-to-end misalignment of up to 150 micrometers or worse. Ideally, the resulting bore would have zero-micrometer end-to-end misalignment, such as perfect concentricity, but this is difficult to achieve in practice. This is due to inherent manufacturing variations in motor components and the manufacturing process's inability to identify and compensate for such variations. The minute deviations introduced by each successive motor component can eventually exacerbate and lead to substantial radial misalignment of the rotor shaft.

[0038] Such end-to-end misalignment along the rotor bore tends to introduce asymmetrical loads on the rotor shaft proportionally, and significantly reduces the motor's operating life, for example, due to rotor assembly wear and the heat generated, as well as introducing acoustic noise due to vibration.

[0039] Therefore, this disclosure generally relates to a technique for radially aligning motor components relative to each other to achieve an electric motor with rotor bores having a submicron end-to-end misalignment, such as less than 50 micrometers and preferably less than 10 micrometers. More specifically, this document discloses a rotor bore alignment tool that can be inserted between multiple motor components, and more specifically, into an orifice / through-hole defined by each of the motor components, such as a housing section and a stator assembly. The rotor bore alignment tool includes a extendable member that can selectively transform to an extended position such that each motor component is radially aligned, and the motor components are subsequently securely joined in a so-called “stack” to form a motor. For example, once the motor components are securely joined together, for example via adhesives and / or screws, the resulting motor includes a rotor shaft extending from end to end, preferably including a submicron misalignment of less than 10 micrometers and more preferably less than or equal to 5 micrometers.

[0040] In one embodiment, an electric motor includes a first housing portion defining a first rotor container to receive and be coupled to a first end of a rotor assembly. The electric motor further includes a second housing portion defining a second rotor container to receive and be coupled to a second end of the rotor assembly. The first and second housing portions are configured to be coupled together and jointly provide a rotor bore to receive the rotor assembly. The rotor assembly is disposed within the rotor bore, wherein the rotor assembly includes a shaft and a first and second bearing concentrically coupled along the shaft. The first bearing may be disposed within the first rotor container of the first housing portion, and the second bearing may be disposed within the second rotor container of the second housing portion. The shaft and the associated first and second bearings are preferably radially aligned with each other based on the rotor bore jointly provided by the first and second housing portions, the first and second housing portions having an end-to-end offset deviation preferably less than 10 micrometers and more preferably less than or equal to 5 micrometers.

[0041] Turning diagram, Figure 1-4 A motor 100 according to an embodiment of the present disclosure is shown. The motor 100 is preferably configured as an electric motor, and more preferably as a brushless DC (BLDC) motor. It should be noted that this disclosure specifically refers to BLDC electric motors, illustrating and describing various aspects and features. However, this disclosure is not limited to this aspect, and is equally applicable to other types of motors, such as brushed motors, with minor modifications.

[0042] The motor 100 includes a housing, which is collectively shown as 102 and separately shown as a first housing portion 102-1, a second housing portion 102-2, and a third housing portion 102-3 (see also...). Figure 3 Therefore, housing 102 may also be referred to herein as a multi-part or multi-portion housing. Housing 102 may be formed of, for example, plastic, metal, or any other suitable ridge material. Preferably, each portion of housing 102 comprises a thermoplastic plastic with relatively high heat resistance and tensile strength. For example, housing 102 is preferably formed of acrylonitrile butadiene styrene (ABS).

[0043] For details, please refer to the following: Figure 3Each of the housing portions 102-1 to 102-3 is configured to be radially aligned with each other along the longitudinal axis 150, such that during manufacturing, the orifices / through holes of each housing portion are substantially aligned when they are joined together. As further discussed below, each of the housing portions 102-1 to 102-3 may include relatively large manufacturing tolerances to allow for relatively coarse-grained adjustments prior to subsequent radial alignment (e.g., via an extendable mandrel conforming to this disclosure) and attachment / fixing stages.

[0044] Next, the first housing portion 102-1 includes a base having a plurality of mating protrusions extending therefrom along a longitudinal axis 150. The mating protrusions are configured to interlock with corresponding mating sections of the second housing portion 102-2. Thus, the first housing portion and the second housing portion can be configured to be joined together via mating protrusions, which may also be referred to herein as interlocking mating portions or simply interlocking portions.

[0045] The mating protrusion preferably includes an offset alignment tolerance of up to 50 micrometers or more, and more preferably between 100 and 150 micrometers. The offset alignment tolerance allows the first housing portion 102-1 and the second housing portion 102-2 to be radially displaced relative to each other, as discussed in further detail below.

[0046] Additionally, the mating protrusion is preferably configured to maintain an angular alignment between the first housing portion 102-1 and the second housing portion 102-2. This angular alignment can be maintained by supplying a compressive force (or clamping force) along the longitudinal axis 150, which causes the first housing portion 102-1 and the second housing portion 102-2 to shift toward each other during manufacturing and clamp together via an extendable mandrel / component, as will be further discussed below.

[0047] Next, at least in part based on the aforementioned corresponding orifices / through holes, the first housing portion 102-1 further defines a first rotor container 104-1, and the second housing portion 102-2 further defines a second rotor container 104-2. The first housing portion 102-1 and the second housing portion 102-2 further define a stator cavity 105 for receiving and aligning stator assemblies such as stator assembly 111 and associated rotor assemblies such as rotor assembly 106, said stator cavity 105 may also be simply referred to herein as a cavity.

[0048] More specifically, each stator component of stator assembly 111 is radially aligned along longitudinal axis 150 and configured to be joined together in a sandwich / stacked configuration. For example... Figure 3As shown, the stator components of stator assembly 111 include a first winding pad 110-1, followed by a stator stack 112 and a second winding pad 110-2. The stator stack 112 may include multiple layers. For example, the stator stack 112 may include multiple iron layers radially aligned with each other.

[0049] The first winding pad 110-1 and the second winding pad 110-2 are configured to receive and hold the winding 108 at a predetermined position relative to the stator stack 112 within the stator cavity 105, such that the winding 108 is arranged around the rotor assembly 106 within the housing 102. The winding 108 may comprise, for example, copper or other suitable material. Thus, the stator components are coupled together and collectively provide a radially aligned stator assembly disposed within the stator cavity 105.

[0050] like Figure 3 As shown, the rotor assembly is commonly shown at 106 and individually at 106-1 to 106-4. Rotor assembly 106 includes a shaft 106-4 and a plurality of components concentrically connected to the shaft 106-4. Specifically, rotor assembly 106 includes a first bearing 106-1, a second bearing 106-2, and a magnet 106-3, each coaxially and concentrically connected to the shaft 106-4.

[0051] The first bearing 106-1 is disposed at the first end of the shaft 106-4 and is at least partially inserted into the first rotor container 104-1. For this purpose, the size / dimension of the first bearing 106-1 can be set such that its diameter is substantially the same as the diameter of the first rotor container to ensure a snug fit with no axial play / skewing.

[0052] The second bearing 106-2 is positioned adjacent to the second end of the shaft 106-4. The second bearing 106-2 is at least partially inserted into the second rotor housing 104-2. The second bearing 106-2 is also sized / dimmed such that it is coupled into the second rotor housing 104-2 without axial clearance.

[0053] The magnet 106-3 is preferably fixedly connected to the midpoint of the shaft 106-4, for example by an adhesive or other attachment method, such that rotation of the shaft 106-4 causes rotation of the magnet 106-3.

[0054] As further shown, following the second winding pad 110-2 are a diffuser 114, a fan (or impeller) 116, a hub 118, and a third housing portion 102-3. The third housing portion 102-2 may also be referred to as a shroud.

[0055] Turning Figure 4 And refer to other sources. Figure 3The figure shows a cross-sectional view of the motor 100 after its components have been radially aligned and securely joined together. As shown, the shaft hole (also referred to herein as the hole) is formed by the orifice / through hole of each component of the motor 100 aligned along the longitudinal axis 150, wherein the hole has the maximum nominal end-to-end offset deviation.

[0056] In the context of motor holes, end-to-end misalignment generally refers to the maximum radial deviation between each radially / concentrically aligned hole / orifice. For example, a 50-micrometer radial deviation / displacement between the orifices / through holes of the first housing portion 102-1 and the second housing portion 102-2 would introduce an end-to-end misalignment of at least 50 micrometers, assuming, for instance, that other motor components do not have a larger misalignment.

[0057] Figure 4 The example bore preferably has an end-to-end offset deviation between 10 and 50 micrometers, 10 micrometers ± 5 micrometers, and more preferably less than or equal to 5 micrometers. Aspects and features of this disclosure recognize that the smaller the end-to-end offset deviation for the bore, the longer the potential operating life of the motor 100. In other words, the closer the bore of the motor 100 is to a substantially zero-deviation opening / hole, such as a perfectly concentric bore, the longer the theoretical life of the motor 100 will be based on a symmetrical load along the length of the shaft 106-4 of the rotor assembly 106. Similarly, it is necessary to ensure that the shaft 106-4 is concentrically positioned within the bore of the motor, e.g., without angular misalignment. This alignment is also commonly referred to as the vertical alignment of the shaft 106-4 relative to the motor housing 102.

[0058] In any case, one aspect of this disclosure achieves a submicron end-to-end offset deviation of the holes in the motor 100 to increase maximum motor life and reduce or otherwise mitigate wear of motor components and motor noise caused by misaligned rotor shafts.

[0059] Figure 5 and 6 An example method for achieving the aforementioned submicron offset deviation of the bore in an electric motor is illustrated. As shown, before inserting the rotor assembly 106 into the bore of the motor 100, an extendable mandrel 124 is inserted therein, wherein the extendable mandrel 124 is in a retracted orientation / position. The extendable mandrel 124 may also be referred to herein as a rotor bore alignment device. The extendable mandrel 124 may be formed with an elongated shaft having a substantially uniform diameter along its entire length, and the total length being greater than or equal to the length of the associated rotor bore. Preferably, along its entire length, the diameter of the shaft of the extendable mandrel 124 is maintained within ±10 micrometers, and more preferably less than or equal to 5 micrometers.

[0060] As shown in the figure, the extendable mandrel 124 includes a plurality of extendable members, namely, a first extendable member 126-1, a second extendable member 126-2, and a third extendable member 126-3. Depending on the desired configuration, the extendable mandrel 124 may include more or fewer extendable mandrels. Preferably, the extendable mandrel 124 includes at least one extendable mandrel.

[0061] Each extendable member is positioned at a predetermined location along the axis of the extendable spindle 124. As shown, each of the first extendable member 126-1, the second extendable member 126-2, and the third extendable member 126-3 is positioned at a different location along the axis of the extendable spindle 124. The position of each extendable member is preferably predetermined to be aligned with one or more components of the motor 100, and more preferably with at least the first housing portion 102-1, the second housing portion 102-2, and the stator assembly 111.

[0062] For example, and as Figure 5 As shown, the extendable mandrel 124 is preferably configured to be inserted into a hole in the motor 100, and the flange 128 of the extendable mandrel 124 engaging the outer surface of the motor 100 is prevented from being further inserted. Therefore, each of the first extendable member 126-1, the second extendable member 126-2, and the third extendable member 126-3 can be positioned along the extendable mandrel 124 at a predetermined location such that when the extendable mandrel 124 is positioned within the hole of the motor 100, each extendable member is aligned with a target component of the motor 100, as discussed in more detail below.

[0063] The extendable mandrel 124 further includes an actuating member (or arrangement) 130 and a sleeve 132. The sleeve 132 includes a slidable section that travels linearly along the longitudinal axis of the extendable mandrel 124. The sleeve 132 preferably defines an angled surface forming a V-groove 134. Each V-groove preferably extends radially about the axial direction of the extendable mandrel 124. Each extendable member 126-1 to 126-3 is disposed within an associated V-groove. The sleeve 132 can then slidably increase the width of each V-groove to allow the extendable members 126-1 to 126-3 to transition to a retraction orientation, such that the extendable members 126-1 to 126-3 extend radially from the axial direction by a first distance D1, for example... Figure 5 As shown in the diagram, the first distance D1 can be configured to allow the extendable spindle 124 to be slidably inserted into the hole of the motor 100.

[0064] On the other hand, the sleeve 132 can then slidably reduce the width of each V-groove, for example, via linear movement along the axis of the extendable mandrel 124, and thus “pinch” and displace the extendable member to change it to an extended position / orientation, wherein the displacement of the extendable member causes an increase in the outer diameter of the extendable mandrel and extends radially outward from the axis of the extendable mandrel 124 to a second extendable distance D2. Preferably, the first distance D1 is measured to be preferably between 0 micrometers and 100 micrometers, and more preferably less than 10 micrometers. In a preferred embodiment, with the extendable member in a retracted orientation, the outer diameter of the extendable mandrel 124 can then preferably be measured to be about 9.25 mm. Preferably, the second distance D2 is measured to be preferably between 500 and 800 micrometers, and more preferably 500 ± 100 micrometers. In a preferred embodiment, with the extendable member in an extended orientation, the outer diameter of the extendable mandrel 124 can then preferably be measured to be about 9.7 to 10.0 mm. In this preferred embodiment, the outer diameter of the extendable mandrel 124 increases / decreases uniformly along the entire length of the extendable mandrel 124, such that the extendable members extend from the axis of the extendable mandrel 124 within a distance of ±5 micrometers from each other when changing from a retraction orientation to an extension orientation, and vice versa.

[0065] Each extendable member 126-1 to 126-3 preferably comprises an elastic material that allows the aforementioned outer diameter to increase, and thus, through extension, allows each of the extendable members 126-1 to 126-3 to extend to a second distance D2 due to displacement by the associated V-groove. Similarly, by way of example, the material elasticity of the extendable members 126-1 to 126-3 preferably allows them to return to their original state and reduce the outer diameter to a first distance D1 based on the increase and width of the V-groove. Some such example materials with suitable elasticity and stiffness include, for example, nitrile butadiene rubber (NBR), carboxylated nitrile butadiene rubber (XNBR), and / or fluoroelastomers (e.g., VITON™). It should be noted that other methods of extending the outer diameter of the extendable mandrel 124 are within the scope of this disclosure, and the examples provided are not intended to be limiting.

[0066] Next, the extendable members 126-1 to 126-3 can be actuated based on the rotation of the actuating member 130. For example... Figure 5As shown, the actuating member 130 is a threaded screw / shaft that, in response to its rotation, causes a linear displacement / movement of the sleeve 132. Therefore, the actuating member 130 and the sleeve 132 can also be pneumatic and hydraulic, as well as rack and pinion arrangements, wherein the rack and pinion arrangements are configured to convert rotational movement of the actuating member 130 into linear movement of the sleeve 132.

[0067] Therefore, when the extendable mandrel 124 is inserted into the hole of the motor 100, the extendable mandrel 124 reaches a predetermined position (or alignment position) by contacting the side wall of the first housing portion 102-1 with the flange 128, for example. At the predetermined position, the first extendable member 126-1 is preferably aligned with the first housing portion 102-1, the second extendable member 126-2 is preferably aligned with the stator assembly 111, and the third extendable member 126-3 is preferably aligned with the second housing portion 102-2.

[0068] The first extendable member 126-1, the second extendable member 126-2, and the third extendable member 126-3 can then be shifted to an extended position based on, for example, a hydraulic component (not shown) that is firmly connected to and causes rotation of the actuating member 130. In response, the sleeve 132 then slidably engages the extendable member, for example, by reducing the width of each corresponding V-groove, and slidably displaces the extendable member.

[0069] In response, the diameters of the first extendable member 126-1, the second extendable member 126-2, and the third extendable member 126-3 increase, and they extend radially to a second distance D2. Preferably, each of the first, second, and third extendable members 126-1 to 126-3 extends synchronously at substantially the same rate and distance based on the actuating member 130. In any case, when the first, second, and third extendable members 126-1 to 126-3 are rotated to the extended position, a force is applied in a substantially transverse direction relative to the axis of the extendable spindle 124 and, more importantly, to the bore of the motor 100. In response, each of the first housing portion 102-1, the stator assembly 111, and the second housing portion 102-2 is radially displaced by the substantially transverse force transmitted by means of the aligned first extendable member 126-1, the second extendable member 126-2, and the third extendable member 126-3 being rotated to the extended position.

[0070] It is worth noting that the aforementioned radial displacement is at least partially achieved through the offset alignment tolerance 120 provided jointly by the first housing portion 102-1 and the second housing portion 102-2 (see [link]). Figure 4 and 5This is achieved by means of interlocking sections that allow the first housing portion 102-1 and the second housing portion 102-2 to be joined together, allowing a predetermined radial displacement of approximately 50 to 100 micrometers, for example, to provide an offset alignment tolerance 120. Thus, when the extendable mandrel 124 is switched to an extension orientation, the offset alignment tolerance 120 allows the first housing portion 102-1 and the second housing portion 102-2 to be displaced along a direction that extends substantially laterally relative to the bore of the motor 100. The result of this displacement is that the first housing portion 102-1 and the second housing portion 102-2 are radially aligned, achieving submicron radial alignment of the bore formed therebetween (see, for example...). Figure 6 ).

[0071] It is worth noting that the extendable member of the extendable spindle 124 can also introduce a compression / clamping force, which causes the first housing portion 102-1 and the second housing portion 102-2 to shift toward each other, such that the angular alignment of the holes of the motor 100 is achieved by ensuring that the interlocking portions of the first housing portion 102-1 and the second housing portion 102-2 are directly connected to each other, for example, without any gaps between them.

[0072] After the first housing portion 102-1 and the second housing portion 102-2 achieve the aforementioned submicron radial alignment via the extendable mandrel 124, the first housing portion 102-1 and the second housing portion 102-2 can be securely joined to each other via adhesive and / or locking devices. For example, adhesive can be applied to the surface forming the interface between the first housing portion 102-1 and the second housing portion 102-2. Alternatively, or in addition to adhesive, bolts (e.g., metal bolts / rods) or screws can be inserted through the first housing portion 102-1 and the second housing portion 102-2. When screws are used, the screws may optionally include self-tapping heads for penetrating the housing portions.

[0073] After the first housing portion 102-1 and the second housing portion 102-2 are securely connected to each other, the extendable spindle 124 can be redirected back to its retracted orientation, for example, based on the rotation of the actuating member 130. The extendable spindle 124 can then be removed from the hole in the motor 100.

[0074] like Figure 7As shown, the shaft 106-4 of the rotor assembly 106 may include multiple stepped (or shoulder) features, including at least a first stepped feature 134-1 and a second stepped feature 134-2. The first stepped feature 134-1 allows the end of the shaft 106-4 to be inserted into the orifice / through hole of the impeller 116 and flush with the bottom of the first stepped feature 134-1. Therefore, the first stepped feature 134-1 can serve as a mechanical stop that allows the fan to achieve the aforementioned vertical alignment with the shaft 106-4.

[0075] The second-order feature 134-2 includes a protrusion configured to engage a corresponding recess within the motor 100 and prevent further insertion into a hole in the motor 100. For example, as... Figure 8 and 9 As shown, the rotor assembly 106 is inserted into the bore of the motor 100. The second stepped feature 134-2 then engages the groove 136 of the second housing portion 102-2, which acts as a mechanical stop to prevent further insertion of the rotor assembly 106. Therefore, the second stepped feature 134-2 of the rotor assembly 106 and the groove 136 of the second housing portion 102-2 ensure that the rotor assembly 106 is inserted into a predetermined position within the opening of the motor 100 by means of, preferably, only touching the bottom flush. Thus, the predetermined position of the rotor assembly 106 vertically aligned and inserted into the bore of the motor 100 can be achieved by means of the mechanical stop provided by the first stepped feature 134-1 and the second stepped feature 134-2 of the rotor assembly 106.

[0076] like Figure 10B As shown, bearing preload can be achieved via a bearing sleeve of a load spring according to this disclosure. As shown, the bore of motor 100, and more specifically, the first bearing housing 104-1, is at least partially provided by a bearing sleeve 138. The bearing sleeve 138 includes a diameter that receives at least a portion of the diameter of the first bearing 106-1 of the rotor assembly 106.

[0077] Then, for example, in Figure 10A The locking cap 140 shown is coupled to the bearing sleeve 138, for example, based on the threaded portion of the locking cap 140 and the corresponding threaded slot of the bearing sleeve 138, in a radially and axially aligned orientation. The locking cap 140 provides an annular disk that extends substantially laterally relative to the bores of the rotor assembly 106 and the motor 100. A spring device 142, such as a corrugated washer as shown, is disposed between the sidewall of the first housing portion 102-1 and the surface defining the annular disk of the locking cap 140. As further shown, the outer sidewall of the first housing portion 102-1, and more specifically, defines a constraint recess for receiving and retaining the spring device 142 for alignment with the locking cap 140.

[0078] The spring assembly 142 then provides a spring biasing force along an axis that extends substantially parallel to the longitudinal axis of the bore of the rotor assembly 106 and the motor 100, and in a direction substantially away from the motor 100. This spring biasing force thus “pull” (or pulls apart) the bearing sleeve 138 to introduce a preload onto the first bearing 106-1.

[0079] The bearing sleeve 138 may comprise a material with a coefficient of thermal expansion less than that of the material forming the first housing portion 102-1. Therefore, for example, based on heat generated during operation of the motor 100, the first housing portion 102-1 may expand in a direction substantially parallel to the bore of the motor 100 without causing misalignment of the first bearing 106-1. Alternatively, the bearing sleeve 138 maintains a pressure / force against the first bearing 106-1, which can generally be understood as a force “pulling” the rotor assembly 106 toward the locking cap 140. However, the rotor assembly 106 remains radially aligned and secured within the bore of the motor 100 based on, for example, a second stepped feature 134-2 engaging a groove 136 of the second housing portion 102-2.

[0080] Figure 11-13 They are shown respectively Figure 3 An embodiment of diffuser 114. As shown, diffuser 114 includes a cylindrical body 144 that defines an opening / orifice 146 to allow the shaft of rotor assembly 106 to extend through it along longitudinal axis 150 (see Figure 114). Figure 1 and 3 The diffuser 114 further includes a band 148 (or edge) concentrically disposed with and surrounding the cylindrical body 144. The band 148 includes sidewalls extending substantially parallel to the longitudinal axis 150. The band 148 is positioned adjacent to a first end 152-1 of the cylindrical body 144.

[0081] The diffuser 114 further defines a plurality of fins 154 extending radially from the cylindrical body 144. The plurality of fins 154 may also be referred to herein as curved exhaust fins or exhaust fins. Such fins may not necessarily include, for example... Figure 11-13 The curved profile shown can be modified to include other shapes and profiles depending on the desired configuration.

[0082] Each of the plurality of fins 154 abuts the cylindrical body 144 against the band 148 based on a first portion and a second portion 156, the first portion extending from a first end 152-1 of the cylindrical body 144 in a substantially transverse direction relative to the longitudinal axis 150, and the second portion 156 extending from the band 148 and tapering to a position adjacent to a second end 152-2 of the cylindrical body 144. Thus, the band 148 only partially surrounds / encircles the curved exhaust fins, such that the tapered section of each exhaust fin, for example generally shown at 156, is exposed to air and forms a blade-like (or airfoil-like) structure for exhausting air.

[0083] like Figure 13 As shown, multiple fins 154 further define multiple airflow channels, generally shown at 158. Figure 13 As shown, diffuser 114 defines at least three such air diversion channels 158. The air diversion channels 158 are configured to generate air jets extending substantially transversely to the longitudinal axis 150, such that the generated air jets induce cooling on the windings 108 and / or rotor assembly 106 within the motor 100 (see [reference]). Figure 1 and 4 This advantageously introduces cooling for the core components within the motor 100, and compared to an uncooled motor configuration, increases operating life, limits thermal expansion, and allows the motor 100 to maintain nominal power for a longer period of time.

[0084] Figure 14-15 Isolated area shown Figure 3 The third housing portion 102-3. The third housing portion 102-3 may also be referred to as a protective cover. As shown in the figure, one end of the third housing portion 102-3 defines an orifice 199 for receiving air from inside the housing 102. Figure 10B ).

[0085] Figure 16-18 Together they show what is suitable for use Figure 1-4 Motor 100 and / or Figure 23A Another example embodiment of the diffuser 214 in the motor 100'. The diffuser 214 may be configured similarly to the diffuser 114 discussed above to generate an air jet within the motor, and for the sake of brevity, this will not be described again.

[0086] However, and as Figure 16-18 As shown, diffuser 214 does not include the outer edge / band 148 (see...). Figure 11This disclosure has established that omitting the edge / band 148 around the diffuser can improve the aerodynamic performance of the diffuser 214 by reducing the likelihood of countercurrent airflow—e.g., vortex formation—forming along the surface of the associated fins and by reducing the likelihood of unwanted air recirculation within the motor housing, as discussed in more detail below.

[0087] As shown in the figure, diffuser 214 includes a cylindrical body 244 that defines an opening / orifice 246 to allow the shaft of rotor assembly 106 to extend through it along longitudinal axis 150 (see 3). The cylindrical body 244 may also be referred to herein as diffuser body or simply body.

[0088] The diffuser 214 further defines a plurality of fins 254 extending radially from the cylindrical body 244, such that the plurality of fins 254 extend substantially laterally relative to the rotor assembly as the rotor assembly 106 extends through the opening 246. The plurality of fins 254 may be uniformly distributed around the diameter of the cylindrical body 244, and preferably the distance between each fin is uniform. The fins 254 may also be referred to herein as curved exhaust fins or simply as curved fins.

[0089] Preferably, the plurality of fins 254 and the cylindrical body 244 are formed as a single integral material part. For example, the cylindrical body 244 and the fins 254 may be formed from a single composite and / or thermosetting plastic part. However, this disclosure is not limited in this respect, and the cylindrical body 244 and the fins 254 may be formed as separate parts comprising the same or different materials.

[0090] like Figure 16 and 17 As shown, each of the plurality of fins 254 preferably includes a curved profile and extends radially from the cylindrical body 244 to a total length L1. Preferably, the total length L1 is measured to be between 4 mm and 6 mm, and more preferably at least 5 mm. In one example configuration, the total length L1 is measured to be between 10% and 50% of the radius R1 of the cylindrical body 244.

[0091] Each of the plurality of fins 254 includes a top surface 270-1 and a bottom surface 270-2 extending from a first end 272-1 to a second end 272-2. The top surface 270-1 and the bottom surface 270-2 are disposed opposite to each other and extend at a predetermined angle (θ) relative to the top surface 252 defining the first end of the cylindrical body 244 (see [link to documentation]). Figure 17 Preferably, the predetermined angle (θ) is measured to be between 25 and 50 degrees, and more preferably between 30 and 35 degrees.

[0092] Each of the plurality of fins 254 preferably extends from the first end 272-1 to the second end 272-1 to a total height H2. Preferably, the total height H2 is measured to be between 13 mm and 16 mm. In an example configuration, the total height H2 is measured to be equal to or greater than the total height H1 of the cylindrical body 244. Preferably, the total height H1 is measured to be between 9 mm and 10 mm.

[0093] like Figure 17 As shown, each of the plurality of fins 254 preferably includes a first end 272-1 having a distal surface that is substantially flush with a top surface 252 defining a first end of a cylindrical body 244. Each of the plurality of fins 254 further preferably includes a second end 272-2 extending beyond a bottom surface 257 that defines a second end of the cylindrical body 244.

[0094] Preferably, the width W1 from the first end 272-1 to the second end 272-2 of each of the plurality of fins 254 is ( Figure 16 The width W1 of each of the plurality of fins 254 can be measured to be between 1 mm and 2 mm. More preferably, the width W1 of each of the plurality of fins 254 is measured along its respective entire length as 10-25% (0.1 to 0.25) of the maximum value of the total length L1 of each fin extending from the cylindrical body 244. Thus, the ratio of the width W1 of each fin to the length L1 can be between 0.2:1.0 and 0.25:1.0, but other ratios are also within the scope of this disclosure. Thus, each of the plurality of fins 254 can provide a blade-like structure to displace and diffuse air into the motor during operation.

[0095] As discussed above, Figure 16-18 The diffuser 214 shown includes an edgeless configuration, which does not include the edge / band 148 (see...). Figure 11 Therefore, each of the plurality of fins 254 may include a distal portion of the cylindrical body 244 that is not coupled to the adjacent edge structure. In other words, each of the plurality of fins 254 is preferably coupled to the cylindrical body 244 along the region of each fin approaching the cylindrical body 244, such that each fin is fully / completely exposed (e.g., exposed to air) relative to the distal end of the cylindrical body 244. Figure 17 As shown, this may include a distal end provided by surface 259, which extends substantially laterally and is adjacent to the first surface 270-1 and the second surface 270-2, thereby being fully exposed to air.

[0096] Therefore, air can then flow in a first direction along the first surface 270-1 and / or the second surface 270-2, the first direction extending from the first end 271-1 to the second end 272-2 of each fin, and air also flows in a second direction transverse to the first direction to allow air to flow radially outward away from the cylindrical body 244 without being blocked / impeded by, for example, the surface defining the edge 148 (see...). Figure 11 This can advantageously improve aerodynamic performance by minimizing or otherwise reducing vortex formation, which reduces the total amount of recirculated / stagnant air within the motor housing.

[0097] Figures 19-20 An example of a third housing portion 102-3' according to an aspect of this disclosure is shown. The third housing portion 102-3' is compatible with... Figure 1 Motor 100 and / or Figure 23A The motor 100' together serves as the third housing part 102-3 / 2302-3. The third housing part 102-3' may also be referred to herein as a cover.

[0098] The third housing portion 102-3' preferably includes a dome-shaped profile defining an inner cavity 1904. The third housing portion 102-3' may include other shapes / profiles, and Figures 19-20 The examples shown are not intended to be restrictive.

[0099] The third housing portion 102-3' further defines an aperture 1906 at its end communicating with the inner cavity 1904. It should be noted that aperture 1906 can provide aperture 199 when connected to a motor (see...). Figure 10B The third housing portion 102-3' is further preferably provided with a plurality of shoulder / step features, respectively shown as first step feature 1902-1, second step feature 1902-2 and third step feature 1902-3. Figures 19-20 The specific number of step features shown is not intended to be limiting, and more or fewer step features may be used depending on the configuration to be used.

[0100] As discussed in more detail below, one or more such stepped features can be used as mechanical stops to allow the insertion of one or more sealing devices (also referred to herein as sealing devices) to prevent air from entering / leaving the motor 100 through the gap formed between the third housing portion 102-3, the rotor assembly 106 and the fan / impeller 116.

[0101] Figure 22AA cross-sectional view of an example third housing portion 2202-3 is shown, including a cavity 2204 defined by an inner sidewall 2256. When the third housing portion 2202-3 is coupled to a motor, the cavity 2204 may at least partially define an impeller drag chamber. For example, the example third housing portion 2202-3 may... Figure 1 and 23A Used in motor 100 and / or motor 100'.

[0102] As further shown, the inner sidewall 2256 defines a plurality of ribs / protrusions 2258 extending into the cavity 2204. Each of the plurality of ribs 2258 extends substantially parallel to each other and preferably forms a spiral pattern along the entire inner diameter of the cavity 2204.

[0103] When the third housing portion 2102-3 is coupled to the plurality of ribs 2258, the plurality of ribs 2258 are preferably angled along a longitudinal axis 150 substantially parallel to, for example, the longitudinal axis 150 of the motor 100 (see...). Figure 4 The air is guided in a direction extending from the longitudinal axis of the motor. Therefore, the plurality of ribs 2258 may also define at least a portion of the impeller compression chamber within the motor 100. The plurality of ribs 2258 may be formed of the same material as the third housing portion 2202-3, such as ABS plastic, or of different materials such as polyphenylene sulfide (PPS) or steel.

[0104] like Figure 22A as well as Figure 22B As further shown in the partially exploded view, the third housing portion 2202-3 may include a first sealing insert 2262. The first sealing insert 2262 is preferably formed of a deformable material such as a foam material, but other materials for the first sealing insert 2262, such as rubber, are also within the scope of this disclosure. For example, the first sealing insert 2262 may include polytetrafluoroethylene, rubber, and / or nylon.

[0105] The first sealing insert 2262 preferably includes a plurality of annular rings / protrusions 2280 extending radially from the body. The protrusions 2280 may also be referred to herein as O-rings. Preferably, the plurality of annular rings 2280 are configured to extend into corresponding recesses 2278 defined by the third housing portions 2202-3, for example... Figure 22A As shown. In Figure 21 In the cross-sectional view, an example of such a groove is shown more clearly as groove 2178.

[0106] Alternatively, the first sealing insert 2262 may be implemented as a ring that does not necessarily include the annular ring / protrusion 2280. For example, and as... Figure 22CAs shown, the first sealing insert 2262' may include a substantially smooth outer surface. The first sealing insert 2262' may be used when, for example, the third housing portion 2202-3 does not include the recess 2278.

[0107] In any case, advantageously for example, the first sealing insert 2262' can then be located at the distal end / lip of the third housing portion 2202-3 (see... Figure 22A An axial seal 2244 is provided on the surface adjacent to the defining orifice 2206, and / or a radial seal is provided based on the annular protrusion 2280 (see [link]). Figure 22B ).

[0108] refer to Figures 23A-23B Another example motor 100' is shown according to aspects of this disclosure. Motor 100' may be configured substantially similarly to motor 100, and the teachings of motor 100 are equally applicable and will not be repeated for the sake of brevity. It is worth noting that motor 100' may also include submicron radial alignment of an associated rotor assembly utilizing, for example, the extendable mandrel 124 discussed above.

[0109] However, and as shown in the figure, the motor 100' includes a housing, which is collectively shown as 2302, and is individually shown as a first housing portion 2302-1, a second housing portion 2302-2, and a third housing portion 2302-3, each including one or more pressure regulator valves 2390.

[0110] Preferably, the one or more pressure regulator valves 2390 are disposed along the third housing portion 2302-3, and more preferably disposed at a position on the third housing portion 2302-3 near the impeller drag / compression chamber 2392 (see [link]). Figure 23C ).

[0111] Each of the one or more pressure regulator valves 2390 may include a nozzle extending away from the third housing portion 2302-3. Preferably, each nozzle extends radially from the third housing portion 2303-3, for example... Figures 23A-23C As shown in the diagram. Each nozzle may include a barbed profile as shown to allow frictional engagement with the associated hose / pipe, but other nozzle profiles are also within the scope of this disclosure.

[0112] Figure 23C The image shows the motor 100' along an embodiment of the present disclosure. Figure 23B The cross-sectional view captured by the CC line.

[0113] As shown in the figure, each of the one or more pressure regulator valves 2390 includes a first end extending from the third housing portion 2303-3 and defining an inlet. The inlet is in fluid communication with a valve actuator 2391. The valve actuator 2391 selectively connects the channel 2394 to the inlet based on, for example, a drop in air pressure within the channel 2394 below a predetermined threshold. The predetermined threshold can be selected to maintain the pressure within the impeller drag chamber 2392 at a target pressure. For example, the target pressure may be approximately atmospheric pressure + / - 10 PSI, and the valve actuator 2391 can therefore be configured to open based on, for example, a drop in air pressure within the channel 2394 below a first predetermined pressure value of -15 PSI.

[0114] It is noteworthy that the placement of channel 2394 at the distal end of motor 100' (e.g., adjacent to orifice 2399) allows a pressure differential to be introduced along the shoulder 2398 of impeller 2316 relative to impeller drag chamber 2392. Valve actuator 2391 can therefore be configured to induce a pressure differential along shoulder 2398 such that the air pressure near shoulder 2398 is greater than the air pressure within impeller drag chamber 2392. One such example difference includes the air pressure near shoulder 2398 of impeller 2316 being at least 0.1-0.2% greater than the air pressure within impeller drag chamber 2392.

[0115] Preferably, the first sealing insert 2262 provides an airtight seal, for example, with the surface defining the impeller 2316, and prevents air from outside the motor 100' from communicating into the shoulder 2398 of the impeller 2316. Therefore, air recirculation along the shoulder 2398 of the impeller 2316 is then substantially prevented, and instead, air is directed to the components of the motor 100' within the housing 2302 (see [link to housing 2302]). Figure 23A Above.

[0116] like Figure 23C As further shown, diffuser 2314 may include the features described above. Figure 16 and 17 The edgeless configuration discussed further increases the airflow through motor 100' and minimizes or otherwise reduces air recirculation. Therefore, motor 100' can then achieve greater overall efficiency by eliminating heat generated at the stator components within motor 100' based on the increased airflow.

[0117] According to one aspect, a method for aligning sections of an electric motor during manufacturing is disclosed. The method includes: coupling a stator assembly between a first housing portion and a second housing portion to jointly provide a rotor bore extending therethrough; inserting an extendable mandrel into the rotor bore, the extendable mandrel having a retracted position and an extended position, the retracted position providing an outer diameter of the extendable mandrel substantially equal to or smaller than the diameter of the rotor bore to allow insertion therein; rotating the extendable mandrel to the extended position to radially displace the first housing portion, the second housing portion, and the stator assembly relative to each other, such that the rotor bore extending therethrough has an end-to-end axial offset deviation of less than 50 micrometers, more preferably less than 10 micrometers; and securing the first housing portion and the second housing portion to each other after rotating the extendable mandrel to the extended position within the rotor bore, such that the rotor bore maintains the end-to-end axial offset deviation after the extendable mandrel is removed from the rotor bore.

[0118] The method may further include inserting an extendable mandrel into a rotor bore, and further includes inserting the extendable mandrel into a predetermined position within the rotor bore. Inserting the extendable mandrel into the predetermined position may further include flushing the flange of the extendable mandrel with the outer wall of the first housing portion or the second housing portion.

[0119] In the method, inserting the extendable mandrel into a predetermined position may further include aligning the extendable members of the extendable mandrel with each of the first housing portion, the stator assembly, and the second housing portion. Preferably, in the method, rotating the extendable mandrel to an extended position causes the first housing portion, the stator assembly, and the second housing portion to be axially displaced based on the aligned plurality of extendable members. In the method, securing the first housing portion and the second housing portion to each other may further include applying an adhesive to the interface between the first housing portion and the second housing portion. In the method, securing the first housing portion and the second housing portion to each other may further include inserting a screw therebetween.

[0120] According to another aspect of this disclosure, an electric motor is disclosed. The electric motor includes: a first housing portion defining a first rotor container to receive and be coupled to a first end of a rotor assembly; a second housing portion defining a second rotor container to receive and be coupled to a second end of the rotor assembly, the first housing portion and the second housing portion being configured to be coupled together and jointly providing a rotor bore to receive the rotor assembly; and a rotor assembly disposed within the rotor bore, the rotor assembly including a shaft and a first bearing and a second bearing concentrically coupled along the shaft, the first bearing being disposed within the rotor container of the first housing portion, and the second bearing being disposed within the rotor container of the second housing portion.

[0121] The electric motor may further include: a sleeve disposed in a first rotor housing, the sleeve defining an orifice to receive at least a portion of a first bearing; a locking cap radially aligned and coupled to the sleeve, the locking cap providing an annular disc extending substantially laterally relative to the rotor assembly; and a spring disposed between a first housing portion and the annular disc to provide a spring force in a direction substantially parallel to the rotor assembly and remote from the first housing portion, the spring force preloading the first bearing.

[0122] In the electric motor, the first housing portion may include a first material having a first coefficient of thermal expansion, and the sleeve may include a second material having a second coefficient of thermal expansion, the second coefficient of thermal expansion being less than the first coefficient of thermal expansion. In the electric motor, the second housing portion may include a recess adjacent to the rotor bore, the recess engaging a stepped feature of the rotor assembly and preventing further insertion therein. In the electric motor, the spring may include a spring washer, and wherein the spring washer is preferably disposed in a constraint recess defined by the outer wall of the first housing portion.

[0123] According to one aspect of this disclosure, an electric motor is disclosed. The electric motor includes: a first housing portion defining a first rotor container to receive and be coupled to a first end of a rotor assembly; a second housing portion defining a second rotor container to receive and be coupled to a second end of the rotor assembly, the first housing portion and the second housing portion being configured to be coupled together and jointly providing a rotor bore to receive the rotor assembly; and a rotor assembly disposed within the rotor bore, the rotor assembly including a shaft and at least a first bearing concentrically coupled along the shaft, the first bearing being disposed within the first rotor container of the first housing portion or the second rotor container of the second housing portion, and wherein the shaft and the first bearing are radially aligned with each other based on the rotor bore jointly provided by the first housing portion and the second housing portion having an end-to-end offset deviation of less than 10 micrometers.

[0124] According to another aspect of this disclosure, a rotor bore alignment device is disclosed for radial alignment of bores provided by a plurality of housing portions of an electric motor. The rotor bore alignment device includes: a shaft having at least one extendable member disposed along the shaft at a predetermined position, the at least one extendable member selectively transitioning from a retracted orientation to an extended orientation, the retracted orientation causing the at least one extendable member to extend radially from the shaft to a first distance D1, and the extended orientation causing the at least one extendable member to extend radially from the shaft to a second distance D2, the second distance D2 being greater than the first distance D1; and wherein the shaft is configured to be slidably coupled into the bore to a predetermined position, the predetermined position aligning the at least one extendable member with at least a first motor component of the electric motor, such that transitioning the at least one extendable member to an extended orientation causes radial alignment of the first motor component with a second motor component of the electric motor.

[0125] According to one aspect of this disclosure, a diffuser is disclosed for use with an electric motor. The diffuser includes: a cylindrical body defining an opening to allow a rotor assembly shaft to extend through it; and a plurality of curved exhaust fins extending radially from the cylindrical body.

[0126] Although the principles of this disclosure have been described herein, those skilled in the art will understand that this description is by way of example only and is not intended to limit the scope of this disclosure. Other embodiments, in addition to the exemplary embodiments shown and described herein, are also covered within the scope of this disclosure. Those skilled in the art will understand that an electric motor may embody any one or more features included herein, and these features may be used in any particular combination or sub-combination. Modifications and substitutions made by those of ordinary skill in the art are considered to be within the scope of this disclosure, which is limited only by the claims.

Claims

1. An electric motor, the electric motor comprising: A first housing portion defines a first rotor container for receiving and coupling to a first end of a rotor assembly; A second housing portion defining a second rotor container to receive and be coupled to a second end of the rotor assembly; the first housing portion and the second housing portion are configured to be coupled together and together provide a rotor aperture to receive the rotor assembly. as well as A rotor assembly disposed within the rotor bore, the rotor assembly including a shaft and at least a first bearing concentrically connected along the shaft, the first bearing being disposed within a first rotor container of a first housing portion or a second rotor container of a second housing portion, wherein the shaft and the first bearing are radially aligned with each other based on the rotor bore provided jointly by the first housing portion and the second housing portion having an end-to-end offset deviation of less than 10 micrometers. Each of the first and second housing portions is connected to each other based on a first interlocking portion and a second interlocking portion, respectively, and wherein the first and second interlocking portions have an offset alignment tolerance of at least 50 micrometers, such that the first and second housing portions are slidably connected together and allow radial displacement of at least 50 micrometers relative to each other. The rotor bore includes an end-to-end offset deviation of less than 10 micrometers, which is a radial displacement based on the first housing portion and the second housing portion being connected together and by means of the offset alignment tolerance of the first interlocking portion and the second interlocking portion.

2. The electric motor of claim 1, wherein the first housing portion and the second housing portion are joined together with an adhesive.

3. The electric motor of claim 1, wherein the first housing portion and the second housing portion are connected to each other based on a locking device.

4. The electric motor according to claim 3, wherein the locking device comprises a self-tapping screw.

5. The electric motor according to claim 3, wherein the locking device comprises a metal bolt.

6. The electric motor of claim 1, further comprising a stator assembly disposed between the first housing portion and the second housing portion and defining at least a portion of the rotor bore.

7. The electric motor of claim 1, further comprising a third housing portion configured to be coupled to the second housing portion, the third housing portion defining an orifice for supplying air to the electric motor.

8. The electric motor of claim 7, wherein the third housing portion includes at least one pressure regulator valve, the at least one pressure regulator valve being in fluid communication with an impeller drag chamber at least partially defined by the third housing portion.

9. The electric motor of claim 8, further comprising a first sealing device arranged adjacent to the orifice to form an airtight seal with the surface of the impeller disposed in the impeller wind resistance chamber.

10. The electric motor of claim 9, wherein the first sealing device includes at least one annular protrusion, and wherein the third housing portion defines at least one groove to receive the at least one annular protrusion to form the hermetic seal.

11. The electric motor of claim 9, wherein the first sealing device is formed of a material comprising foam, polytetrafluoroethylene, rubber and / or nylon.

12. A rotor bore alignment device for radial alignment of bores provided by a plurality of housing portions of an electric motor, the rotor bore alignment device comprising: A shaft having at least one extendable member disposed at a predetermined position along the shaft, the at least one extendable member selectively changing from a retracted orientation to an extended orientation, the retracted orientation causing the at least one extendable member to extend radially from the shaft to a first distance D1, and the extended orientation causing the at least one extendable member to extend radially from the shaft to a second distance D2, the second distance D2 being greater than the first distance D1; and The shaft is configured to be slidably coupled into the hole to a predetermined position, the predetermined position aligning the at least one extendable member with at least a first motor component of the electric motor, such that the at least one extendable member is repositioned to cause the first motor component and the second motor component of the electric motor to be radially aligned.

13. The rotor bore alignment apparatus of claim 12, wherein the at least one extendable member is a plurality of extendable members, and the bore is jointly defined by at least a first housing portion and a second housing portion of the plurality of housing portions and a stator assembly disposed therebetween, and wherein the predetermined position is configured such that a first extendable member, a second extendable member, and a third extendable member of the plurality of extendable members are aligned and engaged with the first housing portion, the stator assembly, and the second housing portion, respectively, such that changing the plurality of extendable members to the extension orientation causes radial alignment of the bore provided by the first housing portion, the stator assembly, and the second housing portion.

14. The rotor hole alignment device according to claim 13, wherein the hole has an end-to-end offset deviation of less than 10 micrometers.

15. The rotor bore alignment device of claim 13, further comprising a flange disposed at an end of the shaft, the flange extending substantially laterally relative to the longitudinal axis of the shaft, wherein the flange is configured to engage a sidewall of the first housing portion or the second housing portion and prevent the shaft from being further inserted into the bore, the flange being configured to engage the sidewall when the shaft is slidably inserted into the predetermined position within the bore.

16. The rotor bore alignment device of claim 12, wherein the at least one extendable member comprises an annular ring configured to increase in diameter and extend radially outward from the axis in response to a change in the at least one extendable member to the extension orientation.

17. The rotor bore alignment device of claim 12, wherein the rotor bore alignment device is configured to introduce a clamping force that extends substantially parallel to the bore and causes the plurality of housing portions to be displaced toward each other and prevents angular and axial displacement of the plurality of housing portions relative to each other.

18. The rotor bore alignment device of claim 12, further comprising a sleeve disposed on the shaft to slidably engage and disengage the at least one extendable member, the sleeve defining at least one V-shaped groove to selectively displace the at least one extendable member based on linear movement of the sleeve.

19. The rotor bore alignment device according to claim 18, further comprising a threaded bolt within the cavity of the shaft, the threaded bolt rotating to displace the sleeve.

20. The rotor bore alignment device of claim 18, wherein the sleeve is configured to displace the at least one extendable member away from the shaft and to change the at least one extendable member to the extension orientation.

21. The rotor bore alignment device of claim 18, wherein the sleeve is configured to be pulled out from the at least one extendable member to allow the at least one extendable member to change to the retraction orientation.

22. The rotor bore alignment apparatus of claim 12, wherein the at least one extendable member comprises a resilient material, the resilientness allowing the at least one extendable member to increase in diameter to extend to the second distance D2 when changing to the extension orientation, and to retract to return to the first distance D1 when changing to the retraction orientation.

23. The rotor bore alignment device according to claim 12, wherein the at least one extendable member comprises nitrile rubber (NBR), carboxylated nitrile rubber (XNBR), and / or a fluoroelastomer.

24. A diffuser used with an electric motor, the diffuser comprising: A cylindrical body having a first end and a second end, and defining an opening extending from the first end to the second end to allow the rotor shaft of the rotor assembly of the electric motor to extend through it; The edge is concentrically arranged with and surrounds the cylindrical body; A plurality of fins adjoin the cylindrical body to the edge, each of the plurality of fins having a first portion extending laterally from the first end of the cylindrical body along a direction relative to the longitudinal axis of the opening, and each of the plurality of fins having a second portion extending from the edge and tapering to a position adjacent to the second end of the cylindrical body. The edge has a height measured in the direction of the longitudinal axis, which is less than the distance from the first end to the second end of the cylindrical body, such that the edge only partially surrounds the plurality of fins, such that the second portion of each of the plurality of fins is exposed to air.

25. The diffuser according to claim 24, wherein, The edge is connected to the cylindrical body by multiple curved exhaust fins.

26. The diffuser of claim 25, wherein each of the plurality of curved exhaust fins includes an edge connecting to a distal end of the cylindrical body opposite to the cylindrical body.

27. The diffuser of claim 24, wherein each of the plurality of curved exhaust fins includes a distal end exposed to air opposite the cylindrical body.

28. The diffuser of claim 24, wherein each of the plurality of curved exhaust fins includes a distal end that is fully exposed to air opposite the cylindrical body.

Images