Outer rotor integrated cross-flow fan and manufacturing method thereof

Abstract

The invention relates to the technical field of cross-flow fans, in particular to an outer rotor integrated cross-flow fan and a manufacturing method thereof.The outer rotor integrated cross-flow fan comprises a wind wheel body connected with a base; the rotor magnetic ring is connected with the base, the rotor magnetic ring is coaxially provided with a steel shaft, the steel shaft is connected with the base, and the rotor magnetic ring, the steel shaft, the base and the wind wheel body form an integrated structure; and the stator structure comprises a stator body formed by plastic package, the stator body is coaxially provided with a shaft hole, and the steel shaft is inserted into the shaft hole, so that a non-contact magnetic suspension gap is kept between the stator body and the rotor magnetic ring. The LED lamp has the effects of reducing noise, reducing the size and improving the heat dissipation effect.

Description

Technical Field

[0001] The present application relates to the technical field of crossflow blowers, and in particular to an outer rotor integrated crossflow blower and a manufacturing method thereof. Background Art

[0002] The crossflow impeller body is multi-bladed, long cylindrical, with forward multi-wing blades. When the crossflow impeller body rotates, the airflow enters the blade grid from the opening of the crossflow impeller body, passes through the interior of the crossflow impeller body, and is discharged into the volute from the blade grid on the other side, forming a working airflow.

[0003] The existing indoor unit of the air conditioner generally uses a cross-flow fan wheel connected to an inner rotor motor to rotate and supply air. Specifically, the general structure of the cross-flow fan is that a metal sleeve, a vibration-damping rubber ring and a metal ring are arranged on the cross-flow fan wheel connected to one side of the inner rotor motor. The three are connected to each other in this order from the inside to the outside. Finally, the metal ring will be injection-molded and connected to the cross-flow fan wheel, and the shaft of the inner rotor motor is inserted into the metal sleeve, and then a set screw is used to turn it into the hole of the sleeve to lock the motor shaft. However, the cross-flow fan using the inner rotor motor will result in a large axial length of the motor, resulting in a large overall structure volume. Secondly, the cross-flow fan fixed by screws is unstable when the cross-flow fan rotates and is prone to noise. In addition, when used in an air conditioner with a smaller matching number, the installation of the inner rotor cross-flow fan will make the internal space of the air conditioner relatively cramped, seriously affecting the heat dissipation of the motor of the indoor unit of the air conditioner, which is not conducive to promotion and application. Summary of the Invention

[0004] In order to reduce noise, reduce volume and improve heat dissipation, the present application provides an outer rotor integrated cross-flow blower and a manufacturing method thereof.

[0005] On the one hand, the present application provides an outer rotor integrated crossflow fan, which adopts the following technical solution: An outer rotor integrated crossflow fan, comprising: The wind wheel body is connected with the base; The rotor magnetic ring is connected to the base. A steel shaft is coaxially provided on the rotor magnetic ring. The steel shaft is connected to the base. The rotor magnetic ring, the steel shaft, the base and the wind wheel body form an integrated structure. The stator structure includes a plastic-encapsulated stator body. The stator body is coaxially provided with an axis hole. The steel shaft is inserted into the axis hole to maintain a non-contact magnetic suspension gap between the stator body and the rotor magnetic ring.

[0006] By adopting the above technical solution, the rotor magnetic ring, steel shaft, base and wind wheel body are designed as an integrated structure, and combined with the plastic-encapsulated stator body and the non-contact magnetic levitation gap, compared with the cross-flow fan using the inner rotor motor in the existing technology, the axial length of the motor is significantly reduced, thereby greatly reducing the overall structural volume and improving the space utilization of the air conditioner indoor unit. It not only avoids the space occupation problem caused by the long axial size of the traditional inner rotor motor, but also significantly optimizes the heat dissipation performance, which is especially suitable for the internal environment of air conditioners with smaller matching numbers. In addition, the design of the magnetic levitation gap reduces mechanical friction, effectively reduces operating noise, further improves the operating stability and quietness of the whole machine, and brings a more comfortable use experience to users.

[0007] Optionally, multiple rotor magnetic rings are provided inside the rotor magnetic ring, and the rotor magnetic rings are evenly distributed along the circumference of the rotor magnetic ring. A stator magnet matching the rotor magnetic ring is provided outside the stator body, and multiple stator magnets are evenly distributed along the circumference of the stator body. The rotor magnetic ring is provided with a fixed magnetic groove, and the fixed magnetic groove is arranged radially along the steel shaft.

[0008] By adopting the above technical solution, a plurality of rotor magnetic rings equidistantly distributed along the circumference are arranged inside the rotor magnetic ring, which can ensure uniform distribution of the magnetic field, thereby improving the smoothness of the motor operation; a matching stator magnet is arranged outside the stator body, and a plurality of stator magnets are equidistantly distributed along the circumference of the stator body, forming a precise magnetic circuit with the rotor magnetic ring, further improving the operating efficiency and stability of the motor; at the same time, it can optimize the magnetic line path, reduce magnetic resistance, and improve magnetic coupling efficiency, thereby reducing energy consumption and enhancing the output performance of the motor; secondly, the rotor magnetic ring is arranged inside the rotor magnetic ring, and it is difficult to know the position of the rotor magnetic ring from the outside; by setting a fixed magnetic groove, it is convenient to confirm the assembly position of the rotor magnetic ring and the stator body, so that the rotor magnetic ring and the stator body maintain a stable position relationship.

[0009] Optionally, the fixed magnetic slots are located between adjacent rotor magnetic rings.

[0010] By adopting the above technical solution, the stator magnetic groove is arranged between adjacent rotor magnetic rings, so that when the rotor magnetic ring is magnetized, the possibility of interference with the magnetic field distribution on the surface of the rotor magnetic ring due to incorrect assembly positions of the stator magnet and the rotor magnetic ring is reduced, thereby ensuring that the surface magnetic properties of the rotor magnetic ring remain stable and will not be affected by the magnetization process. At the same time, it helps to optimize the magnetic circuit structure, improve the magnetic force transmission efficiency, and further enhance the stability and reliability of the cross-flow fan operation.

[0011] Optionally, a plurality of positioning blocks are fixedly connected to the outer wall of the rotor magnetic ring. The positioning blocks are equidistantly arranged along the circumference of the outer wall of the rotor magnetic ring. The positioning blocks are connected to the base, and the rotor magnetic ring is injection-molded and positioned by the positioning blocks.

[0012] By adopting the above technical solution, multiple positioning blocks are set on the outer wall of the rotor magnetic ring. The positioning blocks are evenly distributed along the circumference of the outer wall of the rotor magnetic ring and connected to the base, so that the rotor magnetic ring can be accurately positioned during the injection molding process, ensuring that the relative position between the rotor magnetic ring and the base is accurate, thereby improving the integration accuracy and stability of the overall structure.

[0013] Optionally, a plurality of connection blocks are connected to the inner wall of the rotor magnetic ring, and the connection blocks are arranged at equal intervals along the circumference of the rotor magnetic ring.

[0014] By adopting the above technical solution, the setting of the connecting block can enhance the structural strength of the inner wall of the rotor magnetic ring, reduce the deformation of the rotor magnetic ring due to centrifugal force during high-speed rotation, and reduce the possibility of separation of the rotor magnetic ring and the base. At the same time, the design of the connecting blocks being evenly distributed along the circumference of the rotor magnetic ring ensures uniform force, further improving the stability and reliability of the overall structure.

[0015] Optionally, a silicone ring is provided on the inner wall of the stator body, a bearing is provided inside the silicone ring, the silicone ring is tightly clamped between the bearing and the stator body, and the steel shaft is inserted into the bearing.

[0016] By adopting the above technical solution, the bearing is fixed to the shaft hole by a silicone ring, reducing the wear problem caused by direct contact between the stator body and the steel shaft due to long-term operation, and further reducing the possibility of loosening or deviation during high-speed operation, thereby improving the overall performance and service life of the cross-flow fan. In addition, the silicone material has excellent temperature resistance and can maintain good elasticity and stability in high temperature environments. Even if the silicone should soften at high temperature, the softened silicone has viscosity, which makes the silicone stick to the stator body, further ensuring a close fit between the bearing and the stator body, and extending the service life of the fan.

[0017] Optionally, an annular protrusion is provided on the wall of the shaft hole, and a limiting groove is provided on the outer wall of the silicone ring, and the annular protrusion is located in the limiting groove.

[0018] By adopting the above technical solution, the silicone ring can be firmly installed in the shaft hole, reducing the possibility of axial movement of the silicone ring, improving the installation accuracy and stability of the stator structure, thereby ensuring the consistency of the magnetic levitation gap and further improving the operating efficiency and reliability of the cross-flow blower.

[0019] Optionally, the outer wall of the silicone ring is connected to a plurality of buffer strips, and the buffer strips are arranged circumferentially along the outer wall of the silicone ring.

[0020] By adopting this technical solution, multiple buffer strips connected to the outer wall of the silicone ring effectively absorb vibration and impact generated by the stator structure during operation, reducing noise and improving overall structural stability. The buffer strips are arranged circumferentially along the outer wall of the silicone ring to ensure even force distribution, further enhancing the shock absorption effect and extending the service life of the equipment.

[0021] Optionally, the stator structure further includes a shell, the stator body is arranged inside the shell, the shell is connected to a ring-shaped member, an annular groove is formed between the inner wall of the base and the rotor magnetic ring, and the ring-shaped member is inserted into the annular groove.

[0022] By adopting this technical solution, the housing provides a stable mounting environment for the stator body, enhancing the stability of the overall structure. The ring member, inserted into the annular groove between the inner wall of the base and the rotor magnetic ring, further improves the assembly precision and concentricity between the stator and rotor structures, effectively reducing vibration and noise during operation, and enhancing the performance and reliability of the crossflow blower.

[0023] On the other hand, the present application provides a method for manufacturing an outer rotor integrated crossflow blower, comprising the following steps: S1: placing the rotor magnetic ring in an injection mold, and forming an integrated base at the bottom of the rotor magnetic ring by the first injection molding method to make a rotor magnetic ring-base composite part; S2: placing the rotor magnetic ring-base composite part and the pre-processed steel shaft into the rotor forming mold together, so that the rotor magnetic ring and the steel shaft are coaxial; S3: using a secondary injection molding method to coat the composite part and the steel shaft with thermoplastic engineering plastic; S4: Weld the wind rotor body and the base so that the rotor magnetic ring, steel shaft, base and wind rotor body form an integrated structure; S5: Use the stator body to form a coated plastic-sealed stator by injection molding; S6: Insert the steel shaft into the shaft hole to maintain a non-contact magnetic suspension gap between the stator body and the rotor magnetic ring.

[0024] By adopting this technical solution, the rotor magnetic ring and base are integrated into a single piece, combined with a secondary injection molding method using thermoplastic engineering plastics. This effectively improves the integrity and stability of the rotor structure, while simplifying the assembly process and reducing production costs. Furthermore, the welded connection between the rotor body and the base further enhances the overall structural integrity, while the plastic encapsulation of the stator body not only improves electrical insulation performance but also enhances heat dissipation, significantly improving the crossflow fan's adaptability for use within small air conditioners.

[0025] In summary, this application includes at least one of the following beneficial technical effects: 1. The rotor magnetic ring, steel shaft, base, and impeller body are designed as an integrated structure. This is combined with a plastic-encapsulated stator body and a contactless magnetic levitation gap. Compared to conventional crossflow fans using inner rotor motors, this significantly reduces the motor's axial length, thereby significantly reducing the overall structural volume and improving the space utilization of the air conditioner's indoor unit. This not only avoids the space occupation problem caused by the long axial length of traditional inner rotor motors, but also significantly improves heat dissipation performance, making it particularly suitable for the interior environments of air conditioners with smaller power ratings. In addition, the magnetic levitation gap design reduces mechanical friction and effectively reduces operating noise, further improving the smoothness and quietness of the entire unit, providing users with a more comfortable user experience. 2. The fixed magnetic groove is arranged between adjacent rotor magnetic rings. This reduces the possibility of interference in the magnetic field distribution on the surface of the rotor magnetic ring caused by incorrect assembly positions of the stator magnets and the rotor magnetic rings during the magnetization operation of the rotor magnetic rings. This ensures that the surface magnetic properties of the rotor magnetic rings remain stable and are not affected by the magnetization process. At the same time, it helps to optimize the magnetic circuit structure, improve the magnetic force transmission efficiency, and further enhance the stability and reliability of the crossflow fan operation. 3. The rotor magnet ring and base are integrated into a single piece, combined with a secondary injection molding process using thermoplastic engineering plastics. This effectively improves the integrity and stability of the rotor structure, while simplifying the assembly process and reducing production costs. Furthermore, the welded connection between the rotor body and the base further enhances the overall structural integrity, while the plastic encapsulation of the stator body not only improves electrical insulation performance but also enhances heat dissipation, significantly improving the crossflow fan's adaptability for use within small air conditioners. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is a schematic diagram of the overall structure in the embodiment of the present application.

[0027] Figure 2 It is an overall explosion diagram in the embodiment of the present application.

[0028] Figure 3 It is a half-section schematic diagram of the whole embodiment of the present application.

[0029] Figure 4 It is a structural schematic diagram of the stator body in the embodiment of the present application.

[0030] Figure 5 It is a schematic diagram of the position of the mounting parts in the embodiment of the present application.

[0031] Figure 6 It is a schematic structural diagram of the rotor magnetic ring in an embodiment of the present application.

[0032] Figure 7 Schematic diagram of the position of the bearing in the embodiment of the present application.

[0033] Figure 8It is a schematic diagram of the bearing structure in an embodiment of the present application.

[0034] Figure 9 It is a schematic diagram of the interior of the silicone ring in the embodiment of the present application.

[0035] Description of reference numerals: 1. Wind wheel body; 11. Fixed seat; 12. Connecting seat; 121. Reinforcement rib; 2. Rotor magnetic ring; 21. Steel shaft; 211. Raised ring; 22. Fixed magnetic groove; 23. Positioning block; 24. Connecting block; 3. Stator body; 31. Casing; 311. Terminal pin; 312. Connecting ring; 313. Power cord; 314. Shaft hole; 32. Stator magnet; 33. First cavity; 34. Second cavity; 4. Casing; 41. Ring part; 411. Rubber part; 42. Mounting part; 5. Silicone ring; 51. Engaging hole; 52. Limiting hole; 53. Limiting groove; 6. Bearing; 61. Ring part; 62. Connecting part; 63. Limiting part; 7. Buffer strip. DETAILED DESCRIPTION

[0036] The following is combined with Figure 1-9 This application is described in further detail.

[0037] The embodiments of the present application disclose an outer rotor integrated crossflow blower.

[0038] Reference Figure 1 and Figure 2 , an outer rotor integrated cross-flow fan, comprising a rotor body 1, a rotor magnetic ring 2 and a stator structure, wherein one end of the rotor body 1 is fixedly connected to a base, the rotor magnetic ring 2 is fixedly connected to the end of the base away from the rotor body 1, the rotor magnetic ring 2 is coaxially provided with a steel shaft 21, one end of the steel shaft 21 is fixedly connected to the base, the rotor magnetic ring 2, the steel shaft 21, the base and the rotor body 1 form an integrated structure, the stator structure comprises a plastic-encapsulated stator body 3, the stator body 3 is coaxially provided with an axial hole 314, the steel shaft 21 is inserted into the axial hole 314, so that a non-contact magnetic suspension gap is maintained between the stator body 3 and the rotor magnetic ring 2, and the air gap between the stator body 3 and the rotor magnetic ring 2 is 0.2-2.0mm, thereby achieving the purpose of reducing the axial length of the motor, reducing the overall structural volume, improving the space utilization rate of the air conditioner indoor unit, and improving the heat dissipation effect of the motor.

[0039] Specifically, refer to Figure 2 and Figure 3, multiple rotor magnetic rings are provided inside the rotor magnetic ring 2, so that the rotor magnetic ring is located inside the rotor magnetic ring 2 and is not easily damaged. At the same time, it is convenient to injection-mold and fix the rotor magnetic ring 2 to the base to improve efficiency. The rotor magnetic ring can use high-performance materials such as neodymium iron boron magnets or samarium cobalt magnets to ensure the magnetic field strength and uniformity. Multiple rotor magnetic rings are equidistantly distributed along the circumference of the rotor magnetic ring 2. In this example, the rotor magnetic ring can adopt a twelve-slot ten-pole distribution or a twelve-slot fourteen-pole distribution to make the magnetic field distribution denser and the magnetic flux path shorter. Higher torque can be generated under the same volume, increasing torque, reducing the cogging torque caused by magnetic resistance changes, improving efficiency, making the wind wheel body 1 rotate smoothly, and reducing noise.

[0040] A stator magnet 32 matching the rotor magnetic ring is provided on the outside of the stator body 3, so that the stator magnet 32 is exposed on the surface of the stator body 3, and the air gap between the stator magnet 32 and the rotor magnetic ring 2 is 0.2-2.0mm, which can determine the position of the stator magnet 32. Multiple stator magnets 32 are evenly distributed along the circumference of the stator body 3, forming a magnetic suspension match with the rotor magnetic ring.

[0041] Reference Figure 4 Specifically, the stator body 3 includes a casing 31, a terminal pin 311, a connecting ring 312 and a power cord 313. The axial hole 314 is provided on the top wall of the casing 31 and passes through the bottom wall of the casing 31. There are two terminal pins 311, and the two terminal pins 311 are electrically connected to two adjacent stator magnets 32 respectively. The stator magnets 32 are distributed in a ring shape outside the connecting ring 312 and are fixedly connected to the outer wall of the connecting ring 312. The terminal pins 311 are electrically connected to the power cord 313. The external power supply is connected through the power cord 313 to make the rotor magnetic ring rotate.

[0042] Reference Figure 3 and Figure 4 The outer wall of the rotor magnetic ring is provided with a fixed magnetic groove 22, which is arranged radially along the steel shaft 21 to optimize the magnetic circuit design. When the rotor magnetic ring 2 and the stator body 3 are assembled, the assembly position is guided so that the magnetization operation can be carried out quickly.

[0043] The rotor magnetic ring is distributed in a ring shape with S poles and N poles at intervals, and the fixed magnetic groove 22 is located between adjacent rotor magnetic rings. Specifically, the center line of the fixed magnetic groove 22 is collinear with the dividing line of adjacent rotors. When the rotor magnetic ring is magnetized, the possibility of interference with the magnetic field distribution on the surface of the rotor magnetic ring due to incorrect assembly positions of the stator magnet 32 and the rotor magnetic ring is reduced, thereby ensuring that the surface magnetic properties of the rotor magnetic ring remain stable and will not be affected by the magnetization process, thereby reducing damage to the rotor magnetic ring.

[0044] The base includes a fixing seat 11 and a connecting seat 12. A circular groove is opened through one side of the fixing seat 11. The peripheral wall of the connecting seat 12 is fixedly connected to the peripheral wall of the circular groove. The fixing seat 11 is fixedly connected to the rotor magnetic ring. The connecting seat 12 is fixedly connected to the end of the steel shaft 21 away from the stator body 3.

[0045] A reinforcing rib 121 is fixedly connected to one end of the connecting seat 12 away from the stator body 3. The side of the reinforcing rib 121 adjacent to the connecting seat 12 is fixedly connected to the outer wall of the steel shaft 21. Multiple reinforcing ribs 121 are evenly distributed along the circumference of the steel shaft 21. In this embodiment, the number of reinforcing ribs 121 is 6. The reinforcing ribs 121 strengthen the connection relationship between the steel shaft 21 and the connecting seat 12, reduce the possibility of the steel shaft 21 and the connecting seat 12 being detached, and improve the connection stability of the steel shaft 21.

[0046] Reference Figure 3 and Figure 5 The stator structure also includes a shell 4. The end of the casing 31 away from the rotor magnetic ring 2 is fixedly installed inside the shell 4. The shell 4 can be made of aluminum alloy material and has good heat dissipation performance. A ring-shaped part 41 is fixedly connected to the side of the shell 4 close to the rotor magnetic ring 2. An annular groove is formed between the inner wall of the fixing seat 11 and the rotor magnetic ring 2. The ring-shaped part 41 is inserted into the annular groove, and there is a gap between the ring-shaped part 41 and the shell 4 and the rotor magnetic ring 2. When the cross-flow blower is in use, the fixing seat 11 is covered on the top of the ring-shaped part 41, reducing the possibility of liquid entering the interior of the shell 4 and causing damage to the stator magnet 32.

[0047] A rubber member 411 is provided at the bottom of the annular member 41. The rubber member 411 is annular, and the annular edge of the rubber member 411 fits against the inner wall of the shell 4. A mounting groove is provided on the inner wall of the rubber member 411. The mounting groove runs through the top wall of the rubber member 411. The housing 31 is mounted on the groove wall of the mounting groove. A mounting member 42 is fixedly connected to the inner wall of the shell 4. The mounting member 42 is located at the top of the rubber member 411. The housing 31 is engaged between the rubber member 411 and the mounting member 42, thereby fixing the housing 31 in the shell 4. The rubber member 411 is made of rubber material and acts as a buffer, which facilitates the installation of the housing 31 in the shell 4. At the same time, when the steel shaft 21 rotates, it acts as a buffer to reduce noise.

[0048] Furthermore, a buffer groove is provided on the inner bottom wall of the shell 4. The buffer groove is annular and is located at the bottom of the rubber member 411. The rubber member 411 covers the notch of the buffer groove, so that a cavity is formed at the bottom of the rubber member 411, which is convenient for buffering during the subsequent rotation and operation of the rotor magnetic ring, reducing damage and noise.

[0049] A first cavity 33 is formed between the outer top wall of the casing 31 arranged in the mounting groove and the bottom wall of the rotor magnetic ring 2, and a second cavity 34 is formed between the side of the connecting seat 12 away from the reinforcing rib 121 and the side of the casing 31 close to the connecting seat 12. The height distance of the first cavity 33 is inconsistent with the height distance of the second cavity 34. When the rotor magnetic ring 2 drives the steel shaft 21 to rotate, the first cavity 33 and the second cavity 34 provide moving space for the movement of the rotor magnetic ring 2. Specifically, the height distance of the first cavity 33 is smaller than the height distance of the second cavity 34, and the top wall of the rubber part 411 is located at the middle height position of the first cavity 33, thereby effectively improving the buffering protection of the motor.

[0050] Reference Figure 6 The outer wall of the rotor magnetic ring 2 is fixedly connected with a plurality of positioning blocks 23. The positioning blocks 23 are equidistantly arranged along the circumference of the outer wall of the rotor magnetic ring 2. The positioning blocks 23 are fixedly connected to the fixing seat 11. When the rotor magnetic ring 2 and the fixing seat 11 are injection molded, the rotor magnetic ring 2 is injection-molded and positioned by the positioning blocks 23.

[0051] A plurality of connecting blocks 24 are fixedly connected to the inner wall of the rotor magnetic ring 2. The connecting blocks 24 are arranged equidistantly along the circumference of the rotor magnetic ring 2. The number of connecting blocks 24 matches that of the positioning blocks 23. The center line of the connecting block 24 is collinear with the center line of the positioning block 23, and the extension line passes through the center of the circle, thereby reducing the possibility of tilting of the rotor magnetic ring 2 during injection molding installation, thereby improving the rotation stability of the cross-flow fan.

[0052] Reference Figures 7 to 9 The inner wall of the casing 31 is provided with a silicone ring 5, which is cylindrical. A locking hole 51 is opened at one end side of the silicone ring 5, and a bearing 6 is provided in the locking hole 51. The outer wall of the bearing 6 is tightly attached to the groove wall of the locking hole 51. The silicone ring 5 is tightly clamped between the bearing 6 and the casing 31, and the steel shaft 21 is inserted into the bearing 6. In this example, the silicone ring 5 can be made of heat-resistant silicone material with good elastic properties.

[0053] The hole wall of the shaft hole 314 is provided with an annular protrusion, and the outer wall of the silicone ring 5 is provided with a limiting groove 53. The annular protrusion is located in the limiting groove 53. The limiting groove 53 limits the annular protrusion so that the annular protrusion is stuck in the limiting groove 53, reducing the possibility of the silicone ring 5 moving when the steel shaft 21 rotates, and further improving the rotation stability of the cross-flow blower.

[0054] Specifically, the bearing 6 includes an annular portion 61, a connecting portion 62 and a limiting portion 63. The outer wall of the annular portion 61 is in the shape of an annular spherical arc surface. One end side of the annular portion 61 is fixedly connected to one side of the connecting portion 62. One side of the limiting portion 63 is fixedly connected to the inner wall of the annular portion 61. There are multiple limiting portions 63. In this example, there are three limiting portions 63. The limiting portions 63 are equidistantly arranged along the inner wall of the annular portion 61. The limiting portions 63 are fixedly connected to the connecting portion 62. The limiting portions 63 are equidistantly distributed circumferentially. The ends of the positioning parts 63 that are close to each other form an insertion opening. When the steel shaft 21 is inserted into the insertion opening, the outer wall of the steel shaft 21 fits against the wall of the insertion opening, and the annular part 61 fits against the inner wall of the silicone ring 5. The annular part 61 squeezes the inner wall of the engaging hole 51, so that the inner wall of the silicone ring 5 is recessed into a groove that fits against the outer wall of the annular part 61, thereby limiting the position of the steel shaft 21, so that the steel shaft 21 can rotate around a fixed axis under the limiting action of the insertion opening, thereby improving the rotation stability of the wind wheel and reducing noise at the same time.

[0055] A limiting hole 52 is provided on the groove wall away from the slot opening of the engaging hole 51, and the limiting hole 52 is communicated with the engaging hole 51 to facilitate heat dissipation. The limiting hole 52 and the engaging hole 51 are both circular holes and are coaxially arranged. The diameter of the engaging hole 51 is larger than the diameter of the limiting hole 52. When the cross-flow fan is placed vertically for use, the engaging hole 51 is located at the top of the limiting hole 52. Under the influence of gravity, the bearing 6 may move downward. The diameter of the engaging hole 51 is larger than the diameter of the limiting hole 52, which can support and limit the bearing 6 and reduce the possibility of the bearing 6 detaching from the silicone ring.

[0056] In this embodiment, the bearing 6 can be made of rubber to further reduce noise.

[0057] The outer wall of the silicone ring 5 is connected to a plurality of buffer strips 7, which are convex and arranged on the outside of the silicone ring 5. The buffer strips 7 are arranged circumferentially along the outer wall of the silicone ring 5 so that there are gaps between adjacent buffer strips 7 to facilitate heat dissipation. The buffer strips 7 can be made of rubber material with good buffering performance, which is used to absorb vibration and reduce noise.

[0058] A raised ring 211 is fixedly connected to the outer wall of the steel shaft, and one side of the raised ring 211 is fixedly connected to the connecting seat 12. There is a gap between the side of the raised ring 211 away from the connecting seat 12 and the silicone ring 5. Therefore, when the steel shaft 21 rotates, the gap between the raised ring 211 and the connecting seat 12 acts as a buffer, facilitating the stable rotation of the steel shaft 21 and reducing noise.

[0059] At the same time, the rubber part 411 supports the casing 31 so that there is a gap between the casing 31 and the inner wall of the shell 4. The outer wall of the casing 31 is provided with a heat dissipation groove, so that the heat generated by the steel shaft 21 flows through the engaging hole 51, the limiting hole 52, the gap between the casing 31 and the inner wall of the shell 4, the heat dissipation groove, the gap between the shell 4 and the annular part 41, and the gap between the rotor magnetic ring 2 and the annular part 41, thereby being discharged out of the fan to improve the heat dissipation effect.

[0060] The overall advantages of this embodiment are: by adopting an external rotor drive structure, the axial length of the motor is effectively reduced, the overall structural volume is reduced, the space utilization rate of the air-conditioning indoor unit is improved, and the heat dissipation effect of the motor is improved, which is conducive to its promotion and application in air-conditioning with smaller matching numbers. The magnetic levitation matching design improves the operating efficiency and stability of the cross-flow fan. Secondly, the rotor magnetic ring 2 is directly installed on the fixed seat 11 to improve rotation stability and reduce noise.

[0061] The present application also discloses a method for manufacturing an outer rotor integrated crossflow blower, which specifically includes the following steps: S1: placing the rotor magnetic ring 2 in an injection mold, and forming an integrated base at the bottom of the rotor magnetic ring 2 by a first injection molding method to produce a rotor magnetic ring 2-base composite part; S2: Place the rotor magnetic ring 2-base composite part and the pre-processed steel shaft 21 into the rotor forming mold, so that the rotor magnetic ring 2 and the steel shaft 21 are coaxial; S3: using a secondary injection molding method to coat the composite part and the steel shaft 21 with thermoplastic engineering plastic; S4: Welding the wind rotor body 1 to the base, so that the rotor magnetic ring 2, the steel shaft 21, the base and the wind rotor body 1 form an integrated structure; S5: forming the stator body 3 into a coated plastic-encapsulated stator by injection molding; S6: Insert the steel shaft 21 into the shaft hole 314 to maintain a non-contact magnetic suspension gap between the stator body 3 and the rotor magnetic ring 2.

[0062] Specifically, in step S1, a fixing seat 11 is formed at the bottom of the rotor magnetic ring 2 through a first injection molding method to form a rotor magnetic ring 2-fixing seat 11 composite. After the rotor magnetic ring 2-fixing seat 11 composite is cooled and formed, in step S2, the rotor magnetic ring 2-fixing seat 11 composite and the pre-processed steel shaft 21 are placed together into the rotor forming mold, so that the rotor magnetic ring 2 and the steel shaft 21 are coaxial, and finally a complete rotor magnetic ring 2, steel shaft 21 and base integrated structure is formed. The segmented injection molding process can effectively avoid the problem of deformation of the rotor magnetic ring 2 due to excessive temperature during one-time injection molding, while improving the heat dissipation performance and structural strength of the rotor magnetic ring 2.

[0063] The above are all preferred embodiments of the present application. These embodiments are only explanations of the present application and do not limit the scope of protection of the present application in turn. Therefore, all equivalent changes made based on the structure, shape, and principle of the present application should be covered within the scope of protection of the present application.

Claims

1. An outer rotor integrated crossflow fan, characterized in that: include: A wind wheel body (1) connected to a base; The rotor magnetic ring (2) is connected to the base, the rotor magnetic ring (2) is coaxially provided with a steel shaft (21), the steel shaft (21) is connected to the base, and the rotor magnetic ring (2), the steel shaft (21), the base and the wind wheel body (1) form an integrated structure; The stator structure comprises a plastic-encapsulated stator body (3), wherein the stator body (3) is coaxially provided with an axial hole (314), and a steel shaft (21) is inserted into the axial hole (314), so that a non-contact magnetic suspension gap is maintained between the stator body (3) and the rotor magnetic ring (2).

2. The outer rotor integrated crossflow fan according to claim 1, characterized in that: A plurality of rotor magnetic rings are provided inside the rotor magnetic ring (2), and the rotor magnetic rings are equidistantly distributed along the circumference of the rotor magnetic ring (2); a stator magnet (32) matching the rotor magnetic ring is provided outside the stator body (3), and the plurality of stator magnets (32) are equidistantly distributed along the circumference of the stator body (3); the rotor magnetic ring (2) is provided with a fixed magnetic groove (22), and the fixed magnetic groove (22) is arranged radially along the steel shaft (21).

3. The outer rotor integrated crossflow fan according to claim 1, characterized in that: The fixed magnetic slots (22) are located between adjacent rotor magnetic rings.

4. The outer rotor integrated crossflow fan according to claim 1, characterized in that: A plurality of positioning blocks (23) are fixedly connected to the outer wall of the rotor magnetic ring (2), the positioning blocks (23) are equidistantly arranged along the circumference of the outer wall of the rotor magnetic ring (2), the positioning blocks (23) are connected to the base, and the rotor magnetic ring (2) is injection-molded and positioned by the positioning blocks (23).

5. The outer rotor integrated crossflow fan according to claim 1, characterized in that: The inner wall of the rotor magnetic ring (2) is connected to a plurality of connection blocks (24), and the connection blocks (24) are arranged at equal distances along the circumference of the rotor magnetic ring (2).

6. The outer rotor integrated crossflow fan according to claim 1, characterized in that: A silicone ring (5) is provided on the inner wall of the stator body (3), a bearing (6) is provided inside the silicone ring (5), the silicone ring (5) is tightly clamped between the bearing (6) and the stator body (3), and the steel shaft (21) is inserted into the bearing (6).

7. The outer rotor integrated crossflow fan according to claim 1, characterized in that: The hole wall of the shaft hole (314) is provided with an annular protrusion, the outer wall of the silicone ring (5) is provided with a limiting groove (53), and the annular protrusion is located in the limiting groove (53).

8. The outer rotor integrated crossflow fan according to claim 1, characterized in that: The outer wall of the silicone ring (5) is connected to a plurality of buffer strips (7), and the buffer strips (7) are arranged along the circumference of the outer wall of the silicone ring (5).

9. The outer rotor integrated crossflow fan according to claim 1, characterized in that: The stator structure also includes a shell (4), the stator body (3) is arranged inside the shell (4), the shell (4) is connected to a ring member (41), an annular groove is formed between the inner wall of the base and the rotor magnetic ring (2), and the ring member (41) is inserted into the annular groove.

10. A method for manufacturing an outer rotor integrated crossflow fan, using the outer rotor integrated crossflow fan according to any one of claims 1 to 9, characterized in that: The following steps are involved: S1: placing the rotor magnetic ring (2) in an injection mold, and forming an integrated base at the bottom of the rotor magnetic ring (2) by a first injection molding method to produce a rotor magnetic ring (2)-base composite part; S2: placing the rotor magnetic ring (2)-base composite and the pre-processed steel shaft (21) into a rotor forming mold, so that the rotor magnetic ring (2) and the steel shaft (21) are coaxial; S3: using a secondary injection molding method to coat the composite part and the steel shaft (21) with thermoplastic engineering plastic; S4: welding the wind rotor body (1) and the base, so that the rotor magnetic ring (2), the steel shaft (21), the base and the wind rotor body (1) form an integrated structure; S5: forming the stator body (3) into a coated plastic-encapsulated stator by injection molding; S6: Insert the steel shaft (21) into the shaft hole (314) so that a non-contact magnetic suspension gap is maintained between the stator body (3) and the rotor magnetic ring (2).

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