Rotor for an axial flux electric machine, manufacturing method for the rotor, axial flux electric

Abstract

The invention relates to the technical field of motors, in particular to a rotor for an axial flux motor, comprising: a rotor disc having N first accommodating portions and M second accommodating portions, N and M being positive integers; the N magnetic steels are respectively positioned in the N first accommodating parts; and the sizing material is used for fixing the rotor disc and the magnetic steel with each other, and forms a matching structure with the rotor disc in the second accommodating part after being solidified. The invention also relates to a manufacturing method for the rotor, an axial flux motor and a vehicle. By adopting an integrated design, the rotor disc and the magnetic steel are fixedly connected through a sizing material to form an integrated structure, the manufacturing process is simplified, and the production efficiency is improved. The rotor weight is reduced while the motor performance is ensured, and the power density and the torque density of the motor are improved. By utilizing the mechanical property of the solidified sizing material, the strength of the rotor is improved, the motor is allowed to stably operate at a higher rotating speed, the iron loss and the heat loss are reduced, the efficiency of the motor under a high-speed working condition is improved, and the rated power ratio of the motor is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of motors, and in particular to a rotor for an axial flux motor, a manufacturing method for the rotor, an axial flux motor and a corresponding vehicle. Background Art

[0002] Axial flux motor (also called "disc motor" or "disc motor") is a motor with a special structure, whose magnetic lines of force are parallel to the motor axis. In the prior art, the rotor of the axial flux motor usually adopts a split design, that is, the rotor disk and the magnetic steel (also called "special-shaped magnetic steel") are manufactured separately and then assembled. However, this manufacturing method has the following defects: first, the fixing strength between the magnetic steel and the rotor disk is limited, and it may become loose or even fall off when the motor runs at high speed; second, because a large amount of iron core material is used in the rotor, the rotor will produce large iron loss when running at high speed, reducing the efficiency of the motor.

[0003] Therefore, there is still a practical need for further improvement in the manufacture of rotors for axial flux motors. Summary of the invention

[0004] In view of this, an object of the present invention is to provide an improved rotor for an axial flux motor, an improved manufacturing method for a rotor, an improved axial flux motor and a corresponding vehicle, so as to at least solve part of the problems in the prior art and / or overcome other possible disadvantages not mentioned in this document.

[0005] According to a first aspect of the present invention, a rotor for an axial flux motor is provided, wherein the rotor comprises: a rotor disk having N first accommodating portions and M second accommodating portions, wherein N and M are positive integers respectively; and N magnetic steels, wherein the N magnetic steels are respectively located in the N first accommodating portions; and a rubber material for fixing the rotor disk and the N magnetic steels to each other, wherein the rubber material forms a matching structure with the rotor disk at least in the M second accommodating portions after solidification.

[0006] According to an optional embodiment of the present invention, the rotor is configured to rotate around a rotation axis in the axial flux motor, the rotor disk has a first side and a second side opposite to each other on the rotation axis, and the second accommodation portion is constructed as a through hole penetrating the first side and the second side.

[0007] According to an optional embodiment of the present invention, each second accommodation portion is located between every two adjacent first accommodation portions.

[0008] According to an optional embodiment of the present invention, the matching structure is configured as an undercut connection structure.

[0009] According to an optional embodiment of the present invention, the M second accommodation portions are evenly distributed around the rotation axis.

[0010] According to an optional embodiment of the present invention, the M second receiving portions are located in an outer peripheral region of the rotor disk with reference to the rotation axis.

[0011] According to an optional embodiment of the present invention, the N magnetic steels are located on the first side, and the rubber has a cut-off portion on the second side after solidification.

[0012] According to an optional embodiment of the present invention, the through hole has a central axis parallel to the rotation axis.

[0013] According to an optional embodiment of the present invention, the rotor disk also has K connecting holes evenly distributed around the rotation axis and the rotor includes K bolts suitable for fixedly connecting to other components of the axial flux motor (such as the rotor shaft) through the connecting holes, wherein K is a positive integer (preferably six).

[0014] According to an optional embodiment of the present invention, the glue covers the N magnetic steels on the first side after solidification.

[0015] According to an optional embodiment of the present invention, a peripheral wall of the through hole is inclined and diffused from the first side toward the second side.

[0016] According to an optional embodiment of the present invention, the coating thickness of the glue on each magnetic steel after solidification is at least 0.8 mm.

[0017] According to an optional embodiment of the present invention, the peripheral wall of the through hole has a slope of about 5° with reference to the central axis.

[0018] According to an optional embodiment of the present invention, each magnet has a radial extension of at least 120 mm with reference to the rotation axis.

[0019] According to an optional embodiment of the present invention, the rubber compound contains polyphenylene sulfide resin and glass fiber.

[0020] According to an optional embodiment of the present invention, the viscosity of the rubber at 150° C. is less than 0.06 Pa·s.

[0021] According to an optional embodiment of the present invention, the tensile strength of the rubber after solidification is greater than 50 MPa.

[0022] According to an optional embodiment of the present invention, the rotor disk has a thickness of about 2.5 mm and a diameter of about 360 mm.

[0023] According to an optional embodiment of the present invention, M and N are equal to each other (preferably both are twelve).

[0024] According to a second aspect of the present invention, a method for manufacturing the rotor provided in each embodiment of the first aspect is provided, wherein the manufacturing method comprises the following steps:

[0025] S100: providing an injection mold, wherein the injection mold has a cavity and at least one overflow portion communicating with the cavity;

[0026] S200: placing the rotor disk into the cavity of the injection mold;

[0027] S300: positioning the N magnetic steels in the N first receiving portions of the rotor disk respectively;

[0028] S400: injecting the rubber material into the cavity of the injection mold until the rubber material flows into the overflow portion;

[0029] S500: opening the injection mold and cutting off the overflow portion after the rubber material solidifies.

[0030] According to an optional embodiment of the present invention, in step S400, the glue is injected at a temperature of 100°C to 150°C.

[0031] According to an optional embodiment of the present invention, in step S400, the rubber completely fills the gap between the rotor disk and the N magnetic steels.

[0032] According to an optional embodiment of the present invention, step S500 is performed at a temperature of about 25°C.

[0033] According to an optional embodiment of the present invention, the injection mold has M overflow portions and each overflow portion is located at each second receiving portion of the rotor disk.

[0034] According to a third aspect of the present invention, an axial flux motor is provided, wherein the axial flux motor comprises a first rotor, a second rotor, a stator located between the first rotor and the second rotor, and a rotor shaft connecting the first rotor and the second rotor, wherein the first rotor and / or the second rotor are constructed as the rotors provided in the embodiments of the first aspect above and / or are manufactured using the manufacturing methods provided in the embodiments of the second aspect above.

[0035] According to a fourth aspect of the present invention, a vehicle (especially an electric vehicle or a hybrid vehicle) is provided, wherein the vehicle includes the axial flux motor provided by the embodiments of the third aspect above.

[0036] According to certain embodiments of the present invention, by adopting an integrated design, the rotor disk and the magnetic steel are fixedly connected by rubber to form an integral structure, which not only greatly simplifies the manufacturing process and improves production efficiency, but also significantly enhances the strength and reliability of the rotor assembly. The use of rubber to replace part of the traditional core material effectively reduces the weight of the rotor while ensuring the performance of the motor, and improves the power density and torque density of the motor. In addition, the rubber forms a matching structure in the rotor disk, and the mechanical properties of the rubber after solidification are used to further improve the strength of the rotor assembly, so that the motor can run stably at a higher speed, while significantly reducing iron loss and heat loss, and improving the efficiency of the motor under high-speed conditions, thereby greatly improving the rated power ratio of the motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] The present invention will be described in more detail below with reference to the accompanying drawings, so that the principles, features and advantages of the present invention can be better understood. The accompanying drawings include:

[0038] Figure 1 shows a schematic side view of an axial flux electric machine according to one embodiment of the present invention;

[0039] Figure 2 A schematic perspective view of a rotor for an axial flux electric machine according to an embodiment of the present invention is shown, wherein a first side of a rotor disk is illustrated;

[0040] Figure 3 A schematic perspective view of a rotor for an axial flux electric machine according to an embodiment of the present invention is shown, wherein a second side of the rotor disk is illustrated;

[0041] Figure 4 A schematic top view of a rotor for an axial flux electric machine according to an embodiment of the present invention is shown, wherein a first side of a rotor disk is illustrated;

[0042] Figure 5 Shown along Figure 4 A schematic cross-sectional view taken along the cutting line A1-A1 of ;

[0043] Figure 6 Shows Figure 5 A2 partial enlarged view shown;

[0044] Figure 7 Shows Figure 5 A3 partial enlarged view shown;

[0045] Figure 8 A schematic flow chart showing a method for manufacturing a rotor according to an embodiment of the present invention; and

[0046] Fig. 9A schematic diagram of a vehicle according to an embodiment of the present invention is shown. DETAILED DESCRIPTION

[0047] In order to make the technical problems, technical solutions and beneficial technical effects to be solved by the present invention more clearly understood, the present invention will be further described in detail below in conjunction with the accompanying drawings and multiple exemplary embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention, rather than to limit the scope of protection of the present invention, and that various embodiments may share the same view or multiple views for description, but all features appearing in the same view cannot be interpreted as features that must be possessed by an embodiment.

[0048] Exemplary embodiments of the present invention will be described below with reference to the accompanying drawings.

[0049] Figure 1 FIG. 2 shows a schematic side view of an axial flux motor 2000 according to an embodiment of the present invention. Figure 1 As shown, the axial flux motor 2000 exemplarily adopts an RSR structure, that is, a configuration of dual rotors (Rotor) and a single stator (Stator), and specifically includes a first rotor 2100, a second rotor 2200, a stator 2300 located between the first rotor 2100 and the second rotor 2200, and a rotor shaft 2400 connecting the first rotor 2100 and the second rotor 2200. Here, the first rotor 2100 and / or the second rotor 2200 are configured as the rotor 1000 to be described in detail below and / or are manufactured using the manufacturing method 3000 to be described in detail below. In another embodiment not shown, the axial flux motor 2000 may also adopt other structures, such as an SRS structure, that is, a configuration of dual stators (Stator) and a single rotor (Rotor). Regardless of which configuration structure is adopted, by applying the rotor 1000 and / or the manufacturing method 3000 which will be described in detail below in the axial flux motor 2000, the power density, torque density and efficiency of the motor can be improved, and the dynamic performance and reliability of the motor can be improved. This is because the integrated rotor structure provided according to the embodiment of the present invention can reduce the mass of the rotor, improve the rigidity and strength of the rotor, and reduce the vibration and noise of the rotor, thereby enabling the rotor to remain stable during high-speed operation, thereby extending the service life of the motor.

[0050] Figure 2 A schematic perspective view of a rotor 1000 for an axial flux electric machine 2000 according to an embodiment of the present invention is shown, wherein a first side 901 of a rotor disk 900 is shown; Figure 3 A schematic perspective view of a rotor 1000 for an axial flux electric machine 2000 according to an embodiment of the present invention is shown, wherein a second side 902 of a rotor disk 900 is illustrated.

[0051] like Figure 2 and Figure 3 As shown schematically, the rotor 1000 includes a rotor disk 900, and the rotor disk 900 has N first accommodating portions 910 and M second accommodating portions 920, where N and M are positive integers. The rotor 1000 also includes N magnetic steels 800, and the N magnetic steels 800 are respectively located in the N first accommodating portions 910. In addition, the rotor 1000 also includes a rubber material 700 for fixing the rotor disk 900 and the N magnetic steels 800 to each other. After solidification, the rubber material 700 forms a matching structure 710 with the rotor disk 900 in at least the M second accommodating portions 920 (see also the following description). Figure 7 ).because Figure 2 The first side 901 of the rotor disk 900 is shown to be substantially covered by the rubber compound 700, so that Figure 2 The second receiving portion 920 blocked by the rubber material 700 is schematically shown in FIG. Figure 3 These second receiving portions 920 can be further seen in FIG.

[0052] like Figure 2 As shown, M and N are preferably equal to each other. By setting the number N of the first accommodating parts 910 and the number M of the second accommodating parts 920 to be equal, a favorable pairing relationship between the magnetic steel 800 in the first accommodating part 910 and the rubber material 700 in the second accommodating part 920 can be formed on the rotor disk 900. Further preferably, each second accommodating part 920 is located between every two adjacent first accommodating parts 910. This structure enables the magnetic steel 800 in the first accommodating part 910 and the rubber material 700 in the second accommodating part 920 to be arranged alternately, balance the force of the rotor 1000, reduce the vibration and noise of the rotor 1000, and improve the power performance and service life of the rotor 1000. In the exemplary embodiment shown in the present invention, M and N are both twelve. This design can control the complexity of the rotor 1000 while ensuring the performance of the rotor 1000, and facilitate injection molding and assembly. At the same time, the twelve magnetic steels 800 and the matching structure 710 can also provide sufficient electromagnetic torque and connection strength to meet the use requirements of the axial flux motor 2000. However, it should be understood that within the scope of the present invention, M and N can also be other numbers that are not equal to each other.

[0053] like Figure 2 and Figure 3 Combination Figure 1 As shown, the rotor 1000 is configured to rotate around the rotation axis L0 in the axial flux motor 2000, so the rotor disk 900 of the rotor 1000 has a first side 901 and a second side 902 opposite to each other on the rotation axis L0. In a preferred embodiment, the second receiving portion 920 is configured as a through hole that penetrates the first side 901 and the second side 902 (see also the following description). Figure 7). By providing through holes penetrating both sides of the rotor disk 900 as the second receiving portion 920 , the rubber material 700 can form a matching structure 710 in the through holes connecting both sides of the rotor disk 900 , thereby further enhancing the overall strength and rigidity of the rotor 1000 .

[0054] like Figure 2 and Figure 3 As shown, the twelve second receiving portions 920 are evenly distributed around the rotation axis L0 and are preferably located in the peripheral area of ​​the rotor disk 900 with reference to the rotation axis L0. By evenly distributing the second receiving portions 920 around the rotation axis L0, the matching structure 710 formed by the rubber material 700 can be evenly distributed on the rotor disk 900, balancing the force on the rotor 1000 and reducing the vibration and noise of the rotor 1000. By arranging the second receiving portions 920 in the peripheral area of ​​the rotor disk 900, the matching structure 710 formed by the rubber material 700 can be kept away from the rotation axis L0, increasing the supporting effect of the matching structure 710 on the rotor 1000 and improving the stability of the rotor 1000 during high-speed rotation.

[0055] from Figure 2 and Figure 3 It can be seen that the rotor disk 900 also has K connecting holes 930 evenly distributed around the rotation axis L0, and the rotor 1000 also includes K bolts 600, where K is a positive integer. Here, K is preferably half of M or N, that is, preferably six. It should be understood that by adjusting the number and distribution of the bolts 600 and the connecting holes 930, rotors 1000 of different numbers and sizes can be flexibly connected according to actual needs. Figure 1 For example, the first rotor 2100 configured as the rotor 1000 has six bolts 600, which pass through six connecting holes 930 on the rotor disk 900 and are fixedly connected to the rotor shaft 2400 of the axial flux motor 2000. The rotor shaft 2400 is as shown in FIG. Figure 1 The rotor 2300 is shown to pass through the stator 2300 and is fixedly connected to the second rotor 2200 , which is also configured as the rotor 1000 , for example, thereby achieving a reliable transmission of torque.

[0056] Figure 4 1 shows a schematic top view of a rotor 1000 for an axial flux electric machine 2000 according to an embodiment of the present invention, wherein a first side 901 of a rotor disk 900 is shown; Figure 5 Shown along Figure 4 A schematic cross-sectional view taken along the cutting line A1-A1 of ; Figure 6 Shows Figure 5 A2 partial enlarged view shown; Figure 7 Shows Figure 5 A3 partial enlarged view shown.

[0057] from Figure 7 Combination Figure 5 It can be seen that the matching structure 710 formed by the solidified rubber 700 and the rotor disk 900 in the second receiving portion 920 is an undercut connection structure. Specifically, when the second receiving portion 920 is configured as a through hole, the peripheral wall of the through hole is inclined and diffused from the first side 901 to the second side 902. Figure 7 The second receiving portion 920 as a through hole is open on the left and narrow on the right when viewed downward. This increases the bite force between the solidified rubber 700 and the rotor disk 900, further improves the connection reliability between the rubber 700 and the rotor disk 900, and prevents the rubber 700 from loosening when the rotor 1000 runs at high speed.

[0058] like Figure 7 Combination Figures 2 to 4 As shown, the second receiving portion 920 as a through hole has a central axis L1 parallel to the rotation axis L0. In a preferred embodiment, the peripheral wall of the through hole has a slope of about 5° with reference to the central axis L1. Figure 7 The angle α between the peripheral walls of the through hole is 10°. This angle design can ensure that the rubber material 700 and the through hole are reliably engaged with each other while avoiding excessive inclination that leads to a small cross-sectional area of ​​the through hole, which affects the injection molding of the rubber material 700. The inclination of 5° can form an effective undercut structure while maintaining sufficient filling space in the through hole, which is convenient for the flow and molding of the rubber material 700.

[0059] from Figure 6 and Figure 7 Combination Figure 2 It can be seen that twelve magnetic steels 800 are located on the first side 901 of the rotor disk 900, and the glue 700 covers all twelve magnetic steels 800 on the first side 901 after solidification. Figure 7 As shown, the rubber material 700 has a cut-off portion 701 on the second side 902 of the rotor disk 900 after solidification. During the injection molding process, the rubber material 700 is injected from the first side 901 of the rotor disk 900 and fills the second side 902. After the rubber material 700 solidifies, the excess rubber material 700 is cut off on the second side 902 to form the cut-off portion 701. In this way, the rubber material 700 can completely cover the twelve magnetic steels 800 on the first side 901 of the rotor disk 900, thereby improving the fixing strength of these magnetic steels 800. At the same time, the thickness of the rubber material 700 on the second side 902 is controlled by the cut-off portion 701 to prevent the rubber material 700 from increasing the mass and volume of the rotor 1000 too much. Preferably, as Figure 6As shown schematically, after solidification, the coating thickness d1 of the adhesive 700 on each magnetic steel 800 is at least 0.8 mm. This ensures that the magnetic steel 800 is completely coated by the adhesive 700, thereby improving the fixing strength and protection of the magnetic steel 800. At the same time, the coating thickness of 0.8 mm will not increase the volume and mass of the rotor 1000 too much, thus maintaining a good power density of the rotor 1000. Further preferably, as Figure 6 As shown schematically, after solidification, the rubber compound 700 covers the rotor disk 900 with a thickness d2 of about 1 mm on the first side 901 , and the overall thickness d3 of the rotor 1000 is about 6.3 mm. This ensures that the rubber compound 700 completely covers the rotor disk 900 and the magnet 800 thereon on the first side 901 , further improving the fixing effect of the magnet 800 on the rotor disk 900 .

[0060] like Figure 7 Combination Figure 4 As shown, the rotor disk 900 as a whole has a thickness d0 of about 2.5 mm and a diameter W0 of about 360 mm, and each magnet 800 has a radial extension dimension W1 of at least 120 mm with reference to the rotation axis L0. By arranging the magnet 800 as large as possible on the rotor disk 900 of limited size, the magnetic flux of the rotor 1000 can be increased, the electromagnetic torque of the rotor 1000 can be increased, and the power performance of the motor can be improved. At the same time, the larger size of the magnet 800 is also conducive to increasing the contact area between the magnet 800 and the rubber 700, and enhancing the fixing effect of the magnet 800.

[0061] In the scope of the present invention, the rubber compound 700 is preferably a resin material with high fluidity and high strength. For example, the rubber compound 700 may contain polyphenylene sulfide (PPS) resin and glass fiber. The use of polyphenylene sulfide resin with added glass fiber as the material of the rubber compound 700 can significantly improve the strength and toughness of the rubber compound 700. Glass fiber can enhance the mechanical properties of the rubber compound 700, so that it can withstand greater stress and impact. At the same time, polyphenylene sulfide resin has excellent high temperature resistance and dimensional stability, and is suitable for use in high-speed rotors 1000. The viscosity of this rubber compound 700 is preferably less than 0.06Pa·s at 150°C, and the tensile strength after solidification is preferably greater than 50MPa. By selecting a rubber compound 700 with a viscosity of less than 0.06Pa·s at 150°C, it can be ensured that the rubber compound 700 has good fluidity during the injection molding process, thereby being able to fully fill the gap between the rotor disk 900 and the magnetic steel 800 to form a dense integrated structure. Lower viscosity is also conducive to shortening the injection molding process time and improving production efficiency. By selecting the rubber material 700 with a tensile strength greater than 50 MPa after solidification, it can be ensured that the rubber material 700 has sufficient mechanical strength after solidification, and can reliably connect the rotor disk 900 and the magnetic steel 800. The higher tensile strength also enables the rubber material 700 to withstand the centrifugal force generated when the rotor 1000 rotates at high speed, and maintain the structural stability of the rotor 1000.

[0062] Figure 8 FIG. 3 is a schematic flow chart of a manufacturing method 3000 for manufacturing the rotor 1000 provided in the above-mentioned embodiments according to an embodiment of the present invention. Figure 8 As shown, the manufacturing method 3000 exemplarily includes steps S100 , S200 , S300 , S400 , and S500 .

[0063] First, in step S100, an injection mold is provided, wherein the injection mold has a cavity and at least one overflow portion connected to the cavity. A conventional injection mold generally includes a movable mold and a fixed mold, and when the movable mold and the fixed mold are closed, a cavity having the same shape as the rotor 1000 to be manufactured is formed in the middle.

[0064] Then, in step S200 , the rotor disk 900 is placed into a cavity of an injection mold.

[0065] Next, in step S300 , N magnetic steels 800 (exemplarily twelve magnetic steels 800 ) are respectively positioned in N first receiving portions 910 (exemplarily also twelve first receiving portions 910 ) of the rotor disk 900 .

[0066] Subsequently, in step S400, the injection mold is closed and the rubber material 700 is injected into the mold cavity until the rubber material 700 flows into the overflow portion. Preferably, the rubber material 700 is injected at a temperature of 100°C to 150°C, thereby ensuring that the rubber material 700 has suitable viscosity and fluidity. Further preferably, by controlling the injection amount and injection pressure of the rubber material 700, the rubber material 700 completely fills the gap between the rotor disk 900 and all the magnetic steels 800 during the injection process to avoid the generation of unfilled areas. In a preferred embodiment, the injection mold has M overflow portions (also twelve overflow portions in an exemplary embodiment), each overflow portion is located at each second accommodating portion 920 of the rotor disk 900, that is, the rubber material 700 can flow into the corresponding overflow portion through the second accommodating portion 920 as a through hole during the injection process, thereby ensuring that the rubber material 700 can fully fill each second accommodating portion 920 during the injection process to form a complete matching structure 710. At the same time, these overflow portions form channels that allow excess rubber 700 to overflow. When the cavity of the injection mold is completely filled, excess rubber 700 can be effectively discharged through the overflow portions to avoid defects such as bubble formation inside the rubber during the injection molding process.

[0067] Finally, in step S500, after the rubber material 700 solidifies, the injection mold is opened and all overflow parts are cut off. Preferably, the operating temperature of this step is controlled at room temperature, about 25°C, so that the rubber material 700 can be naturally cooled and solidified at room temperature, avoiding stress and deformation problems that may be caused by high temperature cooling. After the solidification is completed, for example, the movable mold of the injection mold is moved away from the fixed mold to open the injection mold, and finally the overflow material handle is cut off to form the required rotor 1000.

[0068] Fig. 9 A schematic diagram of a vehicle 4000 according to an embodiment of the present invention is shown. Fig. 9 The vehicle 4000 shown is preferably an electric vehicle or a hybrid vehicle, which includes Figure 1The schematically shown axial flux motor 2000 also includes a first rotor 2100 and / or a second rotor 2200 constructed as a rotor 1000 and / or manufactured using the manufacturing method 3000. At present, radial flux motors are commonly used in new energy vehicles on the market, while axial flux motors are less used. The magnetic lines of force of the axial flux motor are parallel to the rotor shaft, while the magnetic lines of force of the radial flux motor are perpendicular to the rotor shaft. Compared with the traditional radial flux motor, the axial flux motor has the advantages of high power density and high torque density. In particular, the overall strength and rigidity of the rotor are improved by the design of integrated molding of the rotor disk, magnetic steel and rubber provided in an embodiment of the present invention. At the same time, the use of rubber materials to replace part of the traditional iron core material reduces the amount of iron core used, reduces the iron loss of the rotor, and improves the efficiency of the motor when running at high speed. As a result, the axial flux motor provided by the embodiment of the present invention can provide more outstanding power performance and energy efficiency under standard operating conditions such as NEDC (New European Driving Cycle), WLTC (World Light Vehicle Test Cycle) and CLTC (China light-duty vehicle test cycle), while also significantly reducing iron loss and heat loss, so that the ratio of rated power to peak power is increased from less than 50% of the traditional radial flux motor to more than 75%, meeting the actual use needs of new energy vehicles.

[0069] Although specific embodiments of the present invention are described in detail herein, they are provided for the purpose of explanation only and should not be considered to limit the scope of the present invention. Various substitutions, changes and modifications may be conceived without departing from the spirit and scope of the present invention.

Claims

1. A rotor (1000) for an axial flux motor (2000), wherein: The rotor (1000) comprises: A rotor disk (900), wherein the rotor disk (900) has N first receiving portions (910) and M second receiving portions (920), wherein N and M are positive integers respectively; and N magnetic steels (800), the N magnetic steels (800) being respectively located in N first receiving portions (910); and A rubber material (700) is used to fix the rotor disk (900) and the N magnetic steels (800) to each other, wherein the rubber material (700) forms a matching structure (710) with the rotor disk (900) in at least the M second receiving portions (920) after solidification.

2. The rotor (1000) according to claim 1, wherein: The rotor (1000) is configured to rotate around a rotation axis (L0) in the axial flux motor (2000), the rotor disk (900) has a first side (901) and a second side (902) that are opposite to each other on the rotation axis (L0), and the second receiving portion (920) is configured as a through hole that penetrates the first side (901) and the second side (902); and / or Each second accommodation portion (920) is located between every two adjacent first accommodation portions (910); and / or The matching structure (710) is configured as an undercut connection structure.

3. The rotor (1000) according to claim 2, wherein: The M second receiving portions (920) are evenly distributed around the rotation axis (L0); and / or The M second receiving portions (920) are located in the outer peripheral region of the rotor disk (900) with reference to the rotation axis (L0); and / or The N magnetic steels (800) are located on the first side (901), and the rubber (700) has a cut-off portion (701) on the second side (902) after solidification; and / or The through hole has a central axis (L1) parallel to the rotation axis (L0); and / or The rotor disk (900) also has K connection holes (930) evenly distributed around the rotation axis (L0), and the rotor (1000) includes K bolts (600) suitable for being fixedly connected to other components of the axial flux motor (2000), such as a rotor shaft, through the connection holes (930), wherein K is a positive integer, preferably six.

4. The rotor (1000) according to claim 3, wherein: The glue (700) covers the N magnetic steels (800) on the first side (901) after solidification; and / or The peripheral wall of the through hole is inclined and diffused from the first side (901) toward the second side (902).

5. The rotor (1000) according to claim 4, wherein: The coating thickness (d1) of the adhesive (700) on each magnetic steel (800) after solidification is at least 0.8 mm; and / or The peripheral wall of the through hole has a slope of about 5° with reference to the central axis (L1); and / or Each magnet (800) has a radial extension (W1) of at least 120 mm with reference to the rotation axis (L0).

6. The rotor (1000) according to any one of claims 1 to 5, wherein: The rubber material (700) contains polyphenylene sulfide resin and glass fiber; and / or The viscosity of the rubber material (700) at 150° C. is less than 0.06 Pa·s; and / or The tensile strength of the rubber (700) after solidification is greater than 50 MPa; and / or The rotor disk (900) has a thickness (d0) of about 2.5 mm and a diameter (W0) of about 360 mm; and / or M and N are equal to each other, and preferably both are twelve.

7. A method (3000) for manufacturing a rotor (1000) according to any one of claims 1 to 6, wherein: The manufacturing method (3000) comprises the following steps: S100: providing an injection mold, wherein the injection mold has a cavity and at least one overflow portion communicating with the cavity; S200: placing the rotor disk (900) into the cavity of the injection mold; S300: positioning the N magnetic steels (800) in the N first receiving portions (910) of the rotor disk (900), respectively; S400: injecting the rubber material (700) into the cavity of the injection mold until the rubber material (700) flows into the overflow portion; S500: After the rubber material (700) solidifies, the injection mold is opened and the overflow portion is cut off.

8. The manufacturing method (3000) according to claim 7, wherein: In step S400, the glue (700) is injected at a temperature of 100°C to 150°C; and / or In step S400, the rubber (700) completely fills the gap between the rotor disk (900) and the N magnetic steels (800); and / or Step S500 is performed at a temperature of about 25° C.; and / or The injection mold has M overflows and each overflow is located at each second receiving portion (920) of the rotor disk (900).

9. An axial flux motor (2000), wherein: The axial flux motor (2000) comprises a first rotor (2100), a second rotor (2200), a stator (2300) located between the first rotor (2100) and the second rotor (2200), and a rotor shaft (2400) connecting the first rotor (2100) and the second rotor (2200), wherein the first rotor (2100) and / or the second rotor (2200) are constructed as a rotor (1000) according to any one of claims 1 to 6 and / or are manufactured using the manufacturing method (3000) according to claim 7 or 8.

10. A vehicle (4000), in particular an electric vehicle or a hybrid vehicle, wherein: The vehicle (4000) comprises the axial flux electric machine (2000) according to claim 9.

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