motor

Abstract

A rotor according to an embodiment of the present disclosure may include a shaft, a plurality of magnets, a housing, and a rotor core. The rotor core may include a plurality of first core layers and a plurality of second core layers. Each of the plurality of first core layers may include: a base member through which the shaft passes; a plurality of core members spaced apart from each other in the circumferential direction of the base member; and a plurality of bridging members, each bridging member extending from a corresponding core member of the plurality of core members toward the base member and bending toward the corresponding core member.

Description

Technical Field

[0001] Various embodiments of this disclosure relate to a rotor comprising a fully split rotor core. Background Technology

[0002] An electric motor is a mechanical device that obtains rotational force from electrical energy. An electric motor consists of a stator and a rotor. The motor rotates due to the electromagnetic interaction between the rotor and the stator.

[0003] Among various types of motors, permanent magnet motors that use permanent magnets to form a magnetic field can be classified into surface permanent magnet (SPM) permanent magnet motors and internal permanent magnet (IPM) permanent magnet motors.

[0004] As a type of IPM permanent magnet motor, the spoke-type permanent magnet motor has a high magnetic flux concentration in its structure, thus enabling it to produce high torque and high output in a smaller size compared to other types of motors with the same power. Accordingly, it can be applied to drive motors that require high torque and high output, such as those used in washing machines or electric vehicles.

[0005] The rotor of a spoked permanent magnet motor includes a shaft, a rotor core through which the shaft passes, and a plurality of magnets (e.g., permanent magnets) inserted into the rotor core.

[0006] Typically, rotor cores are manufactured by pressing thin steel sheets supplied in coils into single sheets, and then stacking them. A rotor core includes a base component through which the shaft passes, a core component arranged circumferentially along the base component, and bridging components connecting the base component and the core component.

[0007] For this type of spoked permanent magnet motor, when the motor is operating, a portion of the magnetic flux may leak toward the shaft through the bridging components of the rotor core, thereby reducing the motor's efficiency. Summary of the Invention

[0008] [Technical Issues]

[0009] Various embodiments of this disclosure may provide a rotor core comprising a plurality of core components divided by stamping operations of a molding apparatus during insert injection molding.

[0010] According to embodiments of this disclosure, a rotor may include: a shaft; a plurality of magnets; a housing; and a rotor core, including a first core layer and a second core layer. The first core layer may include: a base member through which the shaft passes; a plurality of core members spaced apart from each other along the circumferential direction of the base member; and a plurality of bridging members configured such that each of the plurality of bridging members extends from a corresponding core member of the plurality of core members toward the base member and bends toward the corresponding core member.

[0011] According to embodiments of this disclosure, a rotor may include: a shaft; a plurality of magnets; a housing; and a rotor core, including a through hole into which the shaft is inserted, a first core layer, and a second core layer. The first core layer may include: a plurality of core components spaced apart from each other in the circumferential direction of the through hole; and a plurality of bridging components, including pairs of stop protrusions that protrude circumferentially from each side of the outer end of each of the plurality of core components and bend toward the outer end of each of the plurality of core components.

[0012] According to embodiments of the present disclosure, a method for manufacturing a rotor including a shaft, a plurality of magnets, a housing, and a rotor core can be provided. The method includes: forming a rotor core by stacking a first core layer including a plurality of bridging components and a second core layer not including a plurality of bridging components; placing the rotor core on a lower die; mounting a plurality of magnets on the rotor core; and pressing down an upper die having stamping components to stamp the plurality of bridging components of the first core layer.

[0013] According to various embodiments of this disclosure, during insert injection molding, the base component and bridging component of the rotor core can be separated by the stamping operation of the molding equipment, thereby separating the core component connected to the base component. In this case, leakage of magnetic flux to the shaft side through the bridging component can be prevented during motor operation, thus improving motor efficiency.

[0014] Furthermore, since the bridging components, which bend toward the rotor core according to the stamping operation of the molding equipment, are surrounded by the resin constituting the injection molded component during insert injection molding, it is possible to prevent the separate core components from falling off during motor operation.

[0015] For those skilled in the art to which the embodiments of this disclosure pertain, the effects achievable by the exemplary embodiments of this disclosure can be clearly deduced and understood from the following description. In other words, for those skilled in the art to which the embodiments of this disclosure pertain, unexpected effects may also be derived when practicing the exemplary embodiments of this disclosure. Attached Figure Description

[0016] In conjunction with the description of the accompanying drawings, the same or similar reference numerals may be used for the same or similar components.

[0017] Figure 1 This is a perspective view of the rotor according to an embodiment;

[0018] Figure 2 It is along Figure 1 A cross-sectional view taken from line I-I' in the diagram;

[0019] Figure 3 It is along Figure 1 A cross-sectional view taken from line II-II' in the diagram;

[0020] Figure 4 This shows a cross-sectional view of the rotor according to an embodiment;

[0021] Figure 5 This is a perspective view showing the rotor core in its pre-stamping state according to an embodiment;

[0022] Figure 6 It is along Figure 5 A cross-sectional view taken from line III-III' in the diagram;

[0023] Figure 7 This is a plan view showing the rotor core in its pre-stamping state according to an embodiment;

[0024] Figure 8 This is a cross-sectional view of the rotor core in the stamped state according to an embodiment;

[0025] Figure 9 This is a plan view showing the rotor core in the stamped state according to an embodiment;

[0026] Figure 10 It is a graph used to compare the efficiency of the motor before and after the bridging unit is stamped.

[0027] Figure 11 This is a flowchart illustrating the process of manufacturing a rotor according to an embodiment;

[0028] Figure 12a , Figure 12b and Figure 12c This is a diagram illustrating the process of manufacturing the rotor according to an embodiment;

[0029] Figure 13 This shows a side view of the rotor according to an embodiment;

[0030] Figure 14 It is along Figure 13 A cross-sectional view taken from line IV-IV' in the diagram;

[0031] Figure 15 This is a perspective view showing the rotor core before stamping according to an embodiment;

[0032] Figure 16 This is a side view of the rotor core before stamping according to an embodiment;

[0033] Figure 17 This is a plan view of the rotor core before stamping according to an embodiment;

[0034] Figure 18A side view of the stamped rotor core according to an embodiment is shown; and

[0035] Figure 19 This is a plan view showing the stamped rotor core according to an embodiment. Detailed Implementation

[0036] It should be understood that the various embodiments of this disclosure and the terminology used therein are not intended to limit the technical features set forth herein to the particular embodiments, and they may include various changes, equivalents or substitutions to the corresponding embodiments.

[0037] In conjunction with the description of the accompanying drawings, similar reference numerals may be used to denote similar or related elements.

[0038] Unless the relevant context clearly indicates otherwise, the singular form of the noun corresponding to an item may include one or more items.

[0039] As used herein, each phrase such as “A or B”, “at least one of A and B”, “at least one of A or B”, “A, B or C”, “at least one of A, B and C” and “at least one of A, B or C” may include any one or all possible combinations of the items listed together in the corresponding phrase.

[0040] As used herein, terms such as “first” and “second” or “first” and “second” can be used to simply distinguish corresponding components from other components without limiting the components in other ways (e.g., importance or order).

[0041] It should be understood that if the terms “operably” or “communically” are used to refer to an element (e.g., a first element) being “coupled”, “coupled to”, “connected to”, or “connected to” another element, it indicates that the element can be coupled to the other element directly (e.g., wired), wirelessly, or via a third element.

[0042] The terms “comprising,” “including,” or “having” are intended to indicate the presence of the features, quantities, steps, operations, elements, components, or combinations thereof described in this disclosure, but do not preclude the possibility of the presence or addition of one or more other features, quantities, steps, operations, elements, components, or combinations thereof.

[0043] When an element is referred to as being “connected,” “coupled,” “supported,” or “in contact” with another element, or as being “connected to,” “coupled to,” “supported,” or “in contact” with another element, this includes not only cases where the element is directly connected, coupled, supported, or in contact with another element, but also cases where the element is indirectly connected, coupled, supported, or in contact with another element via a third element.

[0044] When a component is referred to as being "above" another component, it includes not only the case where the component is in contact with the other component, but also the case where yet another component exists between the two components.

[0045] The term “and / or” includes any combination of multiple related elements, or any one of multiple related elements.

[0046] The operating principles and embodiments of this disclosure will be described below with reference to the accompanying drawings.

[0047] An electric motor is a mechanical device that converts electrical energy into mechanical energy (such as kinetic energy). An electric motor may include a rotor (e.g., an electromagnetically interacting rotor) that... Figure 1 The motor consists of a rotor 1 and a stator (not shown). The rotor 1 can be rotated by the electromagnetic interaction between the rotor 1 and the stator. Specifically, when current is applied to the stator, the rotor 1 can rotate by the electromagnetic interaction with the stator, and can be powered (e.g., rotational force) by a power device (including the motor) coupled to the rotor 1 in the axial direction.

[0048] Figure 1 This is a perspective view of the rotor according to an embodiment.

[0049] Figure 2 It is along Figure 1 The cross-sectional view taken from line I-I' in the diagram.

[0050] Figure 3 It is along Figure 1 The cross-sectional view taken from line II-II' in the diagram.

[0051] Figure 4 This is a cross-sectional view of the rotor according to an embodiment.

[0052] refer to Figures 1 to 3 According to the embodiment, the rotor 1 may include a shaft 10, a plurality of magnets 20 and a rotor core 100.

[0053] According to an embodiment, shaft 10 can be coupled to rotor core 100. In an embodiment, shaft 10 can be coupled to the interior of rotor core 100 through through hole 101. Shaft 10 can be coupled to rotor core 100 by, for example, insert injection molding.

[0054] According to an embodiment, a plurality of magnets 20 can be inserted into and mounted on the rotor core 100. In an embodiment, the plurality of magnets 20 can be radially located outside the through hole 101 of the rotor core 100. In an embodiment, the plurality of magnets 20 can be configured to be spaced apart from each other by a predetermined gap along the circumferential direction of the through hole 101. Each of the plurality of magnets 20 can be inserted into a slot 103 formed between the split rotor cores 102 of the rotor core 100 and fixed inside the rotor core 100.

[0055] According to an embodiment, the rotor core 100 may include a through hole 101, a plurality of split rotor cores 102 and a plurality of slots 103.

[0056] In one embodiment, a through hole 101 may be formed in the central portion of the rotor core 100. In another embodiment, the through hole 101 may extend vertically. A shaft 10 may be inserted into the through hole 101 and coupled to the rotor core 100.

[0057] In one embodiment, a plurality of split rotor cores 102 may be radially located outside the through-hole 101 of the rotor core 100. The plurality of split rotor cores 102 may be configured to be spaced apart from each other by a predetermined gap along the circumferential direction of the through-hole 101. A plurality of slots 103 for inserting magnets 20 may be formed between the plurality of split rotor cores 102. In another embodiment, the plurality of split rotor cores 102 may be formed by dividing the core components 112 and 121 of stacked core layers 110 and 120 by a stamping operation of the molding equipment 200 during insert injection molding.

[0058] According to an embodiment, the rotor core 100 can be manufactured by stacking multiple thin steel sheets. In an embodiment, the rotor core 100 may include multiple first core layers 110 and multiple second core layers 120 on which multiple thin steel sheets are stacked. In an embodiment, the steel sheets constituting the multiple first core layers 110 and the steel sheets constituting the multiple second core layers 120 may have different shapes. In an embodiment, the rotor core 100 can be formed by alternately stacking multiple first core layers 110 and multiple second core layers 120. The first core layers 110 may be disposed, for example, at the uppermost and lowermost ends of the rotor core 100, but this disclosure is not limited thereto.

[0059] According to an embodiment, the first core layer 110 may include a base component 111, a plurality of first core components 112 and a plurality of bridging components 113.

[0060] According to an embodiment, the base component 111 may have an annular shape. In an embodiment, the base component 111 may include a hole 111a through which the shaft 10 passes.

[0061] According to an embodiment, a plurality of first core components 112 may be spaced apart from the base component 111 by a predetermined gap. In an embodiment, the plurality of first core components 112 may be configured to be spaced apart from each other by a predetermined gap relative to the base component 111 along the circumferential direction of the base component 111.

[0062] According to an embodiment, each of the plurality of first core components 112 may include a pair of stop protrusions 1121 that protrude circumferentially from an outer end 112a toward two opposite sides. In an embodiment, the pair of stop protrusions 1121 may contact the outer surface of a magnet 20 mounted on the rotor core 100 and / or the resin filling the groove 103 and surrounding the magnet 20 to prevent the magnet 20 from detaching from the rotor core 100.

[0063] According to an embodiment, each of the plurality of first core components 112 may include a pair of curved grooves 1122 disposed in an inner end 112b and formed on two opposite sides of the bridging component 113. In an embodiment, the pair of curved grooves 1122 may be formed by cutting or recessing a predetermined cross section from the inner end 112b to the outer end 112a of the first core component 112 on the two opposite sides of the bridging component 113. During insert injection molding, resin may fill the interior of the rotor core 100 through the pair of curved grooves 1122, thereby surrounding the bridging component 113.

[0064] According to an embodiment, a plurality of bridging members 113 may be disposed at corresponding inner ends 112b of a plurality of first core members 112. In an embodiment, at least a portion of the bridging member 113 may be bent to face the inner surface of the first core member 112. In an embodiment, the bridging member 113 may be spaced apart from the base member 111 by a predetermined gap g.

[0065] According to an embodiment, the bridging component 113 may include a connecting portion 1131 extending inward from the inner end 112b of the first core component 112, and a stop portion 1132 bending from the connecting portion 1131 at a predetermined angle.

[0066] In an embodiment, the stop portion 1132 may be bent to be perpendicular to the connecting portion 1131. For example, the stop portion 1132 may extend vertically downward from the extension portion 1131.

[0067] refer to Figure 4 According to an embodiment, the bridging member 113' of the first core layer 110' may include a stop 1133, which extends inward from the inner end 112b of the first core member 112 and is bent at a predetermined angle relative to the first core member 112. Figure 3 The bridging component 113 shown is different. Figure 4 The bridging component 113' shown can be configured as a stop 1133.

[0068] In one embodiment, the stop 1133 may be bent to be inclined relative to the first core member 112. For example, the stop 1133 may extend downward from the first core member 112.

[0069] In the embodiment, the stops 1132 and 1133 can be engaged by the upper mold (e.g., during insert injection molding) during the insertion process. Figure 12b The stamping component 222 (e.g., in the upper die 220) is provided in the upper die 220. Figure 12b The pressing operation of the stamping component 222 in the middle causes the bridging component ( Figure 12b The bridging member 113a is formed separately from the base member 111, and the bridging member 113a is bent to face the inner surface of the first core member 112. In the following text, reference will be made to... Figures 11 to 12c The method for forming the stop parts 1132 and 1133 is described.

[0070] According to an embodiment, the second core layer 120 may include a plurality of second core components 121. In an embodiment, the plurality of second core components 121 may be arranged to be spaced apart from each other by a predetermined gap in the circumferential direction of the through-hole 101 relative to the rotor core 100. In an embodiment, the plurality of second core components 121 may have a substantially the same arrangement or stacking structure as the plurality of first core components 112. For example, the plurality of first core components 112 and the plurality of second core components 121 may be stacked alternately to form a split rotor core 102. In an embodiment, unlike the first core layer 110, the second core layer 120 may not include the base component 111 and the bridging component 113.

[0071] According to an embodiment, the rotor 1 may include an injection-molded component 30 surrounding at least a portion of the rotor core 100. The injection-molded component 30 may also be referred to as a housing.

[0072] In one embodiment, the injection-molded component 30 can be formed by injecting resin into the empty space between the internal gaps of the rotor core 100 and curing it, while a plurality of magnets 20 are mounted on the rotor core 100.

[0073] In this embodiment, a portion of the resin injected into the rotor core 100 can be injected into the interior of the rotor core 100 through the gap g between the base component 111 and the bridging component 113, and a portion of the resin can completely surround the stop portion 1132 of the bridging component 113. In this case, since the multiple split rotor cores 102 are coupled to the injection molding component 30 through the stop portion 1132 of the bridging component 113, the multiple split rotor cores 102 can be prevented from spreading outward due to the rotational force of the motor when the motor is operated.

[0074] Figure 5 This is a perspective view showing the rotor core in its pre-stamping state according to an embodiment.

[0075] Figure 6 It is along Figure 5 The cross-sectional view taken from line III-III' in the diagram.

[0076] Figure 7 This is a plan view showing the rotor core in its pre-stamping state according to an embodiment.

[0077] Figure 8 This is a cross-sectional view of the rotor core in the stamped state according to an embodiment.

[0078] Figure 9 This is a plan view showing the rotor core in the stamped state according to an embodiment.

[0079] Figure 10 It is a graph used to compare the efficiency of the motor before and after the bridging unit is stamped.

[0080] Figures 5 to 7 This diagram shows a rotor core 100a including a first core layer 110a, wherein a plurality of first core components 112 are connected to a base component 111 via bridging components 113a. In other words, Figures 5 to 7 The rotor core 100a, including bridging component 113a, is shown in a forming device (e.g., Figure 12a , Figure 12b and Figure 12c The state before stamping in the forming equipment 200.

[0081] Figure 8 and Figure 9 This is a diagram showing a rotor core 100 including a first core layer 110, wherein a base component 111 and a plurality of first core components 112 are spaced apart from each other. In other words, Figure 8 and Figure 9 The rotor core 100, including the bridging component 113, is shown after being stamped by the forming equipment 200.

[0082] refer to Figures 5 to 7According to an embodiment, the first core layer 110a of the rotor core 100a may include a plurality of bridging members 113a connecting the base member 111 and a plurality of first core members 112. When the plurality of first core members 112 are connected to the base member 111 via the plurality of bridging members 113a, the base member 111, the plurality of first core members 112, and the plurality of bridging members 113a can form a magnetic circuit when the motor is operating. Since magnetic flux leaks toward the shaft 10 through the bridging members 113a, the efficiency of the motor may be reduced.

[0083] To reduce the leakage flux through bridging component 113a, it is necessary to... Figures 1 to 4 As shown, multiple first core components 112 are separated from the base component 111.

[0084] refer to Figure 8 and Figure 9 According to an embodiment, the first core layer 110 of the rotor core 100 may include a bridging member 113 spaced apart from the base member 111 by a predetermined gap. The bridging member 113 of the first core layer 110 and the base member 111 may be separated from each other, thereby forming a gap g therebetween. Each of the plurality of first core members 112 may be separated from the base member 111, so that the base member 111, the plurality of first core members 112 and the bridging member 113 may not form a magnetic circuit, thereby reducing the amount of magnetic flux leaking to the shaft 10 through the bridging member 113.

[0085] refer to Figure 10 It can be seen that when... Figure 8 and Figure 9 When the plurality of first core components 112 shown are separated from the base component 111, as shown in the figure Figures 5 to 7 Compared to when the multiple first core components 112 and base components 111 shown are connected by bridging component 113a, the back electromotive force increases by about ∆V (e.g., about 10%), and in this case, the efficiency of the motor can also be significantly improved (e.g., about 3%).

[0086] In the following text, reference will be made to Figures 11 to 12c A method for manufacturing a rotor core 100 is described, the method comprising separating a plurality of first core components 112 by separating (or stamping) bridging components 113 of a first core layer 110 from a base component 111.

[0087] Figure 11 This is a flowchart illustrating the process of manufacturing a rotor according to an embodiment.

[0088] Figure 12a , Figure 12b and Figure 12c This is a diagram illustrating the process of manufacturing the rotor according to an embodiment.

[0089] Figure 12a This is a diagram showing the state in which the rotor core 100a, to which the shaft 10 is coupled, is placed on the lower mold 210. Figure 12b The diagram shows the state in which the upper mold 220 descends toward the rotor core 100a mounted on the lower mold 210 and the bridging component 113a of the rotor core 100a is stamped. Figure 12c This diagram shows the state in which the rotor 1 is manufactured after the bridging component 113 of the rotor core 100 is stamped, resin is injected into the molding equipment 200 by insert injection molding and cured.

[0090] refer to Figure 11 , Figure 12a , Figure 12b and Figure 12c The method of manufacturing rotor 1 according to the embodiment may include forming rotor core 100a (1110) by alternately stacking a first core layer 110a and a second core layer 120 having different shapes.

[0091] According to an embodiment, a method for manufacturing rotor 1 may include coupling rotor core 100a to shaft 10 by inserting shaft 10 into through hole 101 of rotor core 100a (1120). In some embodiments, after rotor core 100 is insert-molded in step 1140 described below, shaft 10 may be inserted into through hole 101 and coupled to rotor core 100. In this case, the structure of the molding equipment may be partially modified so that through hole 101 of rotor core 100 is not filled with resin during insert injection molding.

[0092] According to an embodiment, a method for manufacturing rotor 1 may include mounting a plurality of magnets 20 inside rotor core 100a (1130). After mounting rotor core 100a on lower mold 210, each of the plurality of magnets 20 may be inserted into and positioned in a slot 103 provided between a plurality of core components 112 and 121.

[0093] According to an embodiment, the method for manufacturing rotor 1 may include step 1140 of stamping a bridging component 113a of rotor core 100a.

[0094] According to an embodiment, the upper die 220 of the forming apparatus 200 may include a pair of stamping members 222 that protrude from a lower surface located at a position facing the bridging member 113a of the rotor core 100a. In an embodiment, the pair of stamping members 222 may include angled, sharp ends 222a at their free ends.

[0095] refer to Figure 12a and Figure 12bIn this embodiment, as the upper die 220 descends toward the rotor core 100a, the stamping component 222 of the upper die 220 contacts the bridging component 113a of the rotor core 100a. Subsequently, as the upper die 220 continues to descend, the bridging component 113a separates from the base component 111 under the clamping force of the upper die 220, and the free end of the separated bridging component 113a bends toward the inner surface of the rotor core 100. As described above, as the bridging component 113a of the rotor core 100a separates from the base component 111 through the pressing operation of the upper die 220, each of the core components 112 and 121 is completely separated.

[0096] According to an embodiment, a method for manufacturing rotor 1 may include: injection molding (1150) the injection-molded component 30 by injecting resin into rotor core 100 and curing it. (See reference) Figure 12c Through step 1140 described above, a gap g is formed between the separate bridging component 113 and the base component 111 of the rotor core 100. When resin is injected into the molding apparatus 200, the resin fills the rotor core 100 through the internal gap (e.g., gap g) and cures. A portion of the injected resin may surround the bridging component 113 and firmly fix the separate rotor core 102 inside the rotor 1.

[0097] Figure 13 This is a side view of the rotor according to an embodiment.

[0098] Figure 14 It is along Figure 13 The cross-sectional view taken from line IV-IV' in the diagram.

[0099] refer to Figure 13 and Figure 14 According to the embodiment, the rotor 1' may include a shaft 10, a plurality of magnets 20, an injection-molded component 30' and a rotor core 300.

[0100] According to an embodiment, the shaft 10 can be coupled to the rotor core 300. In another embodiment, the shaft 10 can be coupled to the interior of the rotor core 300 through a through hole 301.

[0101] According to an embodiment, a plurality of magnets 20 can be inserted into and mounted on the rotor core 300. In an embodiment, the plurality of magnets 20 can be radially located outside the through hole 301 of the rotor core 300. In an embodiment, the plurality of magnets 20 can be configured to be spaced apart from each other by a predetermined gap along the circumferential direction of the through hole 301. Each of the plurality of magnets 20 can be inserted into a slot 303 formed between the split rotor cores 302 of the rotor core 300 and fixed inside the rotor core 300.

[0102] According to an embodiment, the rotor core 300 may include a through hole 301, a plurality of split rotor cores 302 and a plurality of slots 303.

[0103] In one embodiment, a through hole 301 may be formed in the central portion of the rotor core 300. In another embodiment, the through hole 301 may extend vertically. A shaft 10 may be inserted into the rotor core 300 through the through hole 301, and with the shaft 10 passing through the through hole 301, the shaft 10 and the rotor core 300 may be coupled to each other by injecting resin into the through hole 301 and allowing it to cure.

[0104] In one embodiment, multiple split rotor cores 302 may be radially located outside the through-hole 301 of the rotor core 300. In another embodiment, the multiple split rotor cores 302 may be configured to be spaced apart from each other by a predetermined gap along the circumferential direction of the through-hole 301. Multiple slots 303 for inserting magnets 20 may be formed between the multiple split rotor cores 302. In another embodiment, when the core components 311 of the stacked core layers 310 and 120 undergo insert injection molding, the stamping operation of the molding equipment 200 can separate the multiple split rotor cores 302.

[0105] According to an embodiment, the rotor core 300 can be manufactured by stacking multiple thin steel sheets. In an embodiment, the rotor core 300 may include multiple first core layers 310 and multiple second core layers 120 on which multiple thin steel sheets are stacked. In an embodiment, the steel sheets constituting the multiple first core layers 310 and the steel sheets constituting the multiple second core layers 120 may have different shapes. In an embodiment, the rotor core 300 can be formed by alternately stacking multiple first core layers 310 and multiple second core layers 120. The first core layers 310 may be disposed, for example, at the uppermost and lowermost ends of the rotor core 300, but this disclosure is not limited thereto.

[0106] According to an embodiment, the first core layer 310 may include a plurality of first core components 311 and a plurality of bridging components 312.

[0107] According to an embodiment, a plurality of first core components 311 may be configured to be spaced apart from each other by a predetermined gap relative to the through hole 301 along the circumferential direction of the through hole 301. In an embodiment, the resin constituting the injection-molded member 30' may be filled between the plurality of first core components 311 and the shaft 10 inserted into the through hole 301 and cured.

[0108] According to an embodiment, each of the plurality of bridging components 312 may include a pair of stop protrusions 3121 and 3122 that protrude in a circumferential direction from the outer end 311a of the first core component 311 to two opposite sides.

[0109] In one embodiment, a pair of stop protrusions 3121 and 3122 can be bent to face two opposite sides of the first core member 311. In another embodiment, the pair of stop protrusions 3121 and 3122 can extend obliquely from the outer end 311a of the first core member 311 toward another first core member 311 adjacent to it. In yet another embodiment, the stop protrusions 3121 and 3122 of adjacent bridging members 312 can be spaced apart by a predetermined gap.

[0110] According to an embodiment, unlike the first core layer 310, the second core layer 120 may not include the bridging component 312.

[0111] According to an embodiment, the injection-molded component 30' can be formed by injecting resin into the empty space (or cavity) between the internal gaps of the rotor core 300 and curing it, while a plurality of magnets 20 are mounted on the rotor core 300.

[0112] In this embodiment, a portion of the resin injected into the rotor core 300 can be injected into the rotor core 300 through the gap between adjacent bridging members 312, and a portion of the resin can completely surround the stop protrusions 3121 and 3122 of the bridging members 312. Since the multiple split rotor cores 302 are coupled to the injection-molded member 30' through the stop protrusions 3121 and 3122 of the bridging members 312, the multiple split rotor cores 102 can be prevented from spreading outward due to the rotational force of the motor when the motor is operating.

[0113] Figure 15 This is a perspective view showing the rotor core before stamping according to an embodiment.

[0114] Figure 16 This is a side view of the rotor core before stamping according to an embodiment.

[0115] Figure 17 This is a plan view of the rotor core before stamping according to an embodiment.

[0116] Figure 18 This is a side view showing the stamped rotor core according to an embodiment.

[0117] Figure 19 This is a plan view showing the stamped rotor core according to an embodiment.

[0118] Figures 15 to 17 The diagram shows a rotor core 300a including a first core layer 310a, wherein adjacent first core components 311 are connected to each other by a bridging component 312a. Figures 15 to 17 The rotor core 300a, including bridging component 312a, is shown in a forming device (e.g., Figure 12a , Figure 12b and Figure 12c The state before stamping in the forming equipment 200.

[0119] Figure 18 and Figure 19 The diagram shows a rotor core 300 including a first core layer 310, wherein a plurality of first core components 311 are spaced apart from each other. Figure 18 and Figure 19 The state of the rotor core 300, including the bridging component 312, after being stamped by the forming equipment 200 is shown.

[0120] refer to Figures 15 to 17 According to an embodiment, the first core layer 310a of the rotor core 300a may include a bridging member 312a that connects adjacent first core components 311 to each other. When multiple first core components 311 are connected to each other via the bridging member 312a, the leakage flux flowing along the bridging member 312a may reduce the efficiency of the motor when it is in operation.

[0121] To reduce the leakage flux through bridging component 312a, it is necessary to... Figure 13 and Figure 14 As shown, adjacent first core components 311 are separated from each other.

[0122] refer to Figure 18 and Figure 19 According to an embodiment, the first core layer 310 of the rotor core 300 may include a plurality of first core components 311 spaced apart from each other. For example, they can be stamped by forming equipment 200. Figures 15 to 17 A bridging member 312a connects multiple first core components 311a, thereby separating the multiple first core components 311 from each other. In this case, the leakage flux through the bridging member 312a can be reduced.

[0123] According to embodiments of the present disclosure, a rotor 1 may include a shaft 10, a plurality of magnets 20, a housing 30, and a rotor core 100, the rotor core 100 including a plurality of first core layers 110 and a plurality of second core layers 120. The first core layer 120 may include a base member 111 through which the shaft 10 passes. The first core layer 120 may include a plurality of core members 112 and 121 spaced apart from each other along the circumferential direction of the base member 111. The first core layer 120 may include a plurality of bridging members 113 and 113', the plurality of bridging members 113 and 113' being configured such that each of the plurality of bridging members 113 and 113' extends from a corresponding core member of the plurality of core members 112 toward the base member 111 and bends toward the corresponding core member 112.

[0124] According to an embodiment, each of the plurality of bridging components 113 can be bent vertically relative to the corresponding core component 112.

[0125] According to an embodiment, each of the plurality of bridging components 113' can be bent to be inclined relative to the corresponding core component 112.

[0126] According to an embodiment, the plurality of core components of the first core layer 110 may be a plurality of first core components 112, and the second core layer 200 may include a plurality of second core components 121 that are not connected to the plurality of bridging components 113 and 113'.

[0127] According to an embodiment, a plurality of first core layers 110 and a plurality of second core layers 120 may be stacked alternately in the vertical direction.

[0128] According to an embodiment, each of the plurality of bridging components 113 may be spaced apart from the base component 111 by a predetermined gap g.

[0129] According to an embodiment, each of the plurality of core components 112 may include a pair of curved grooves 1122, which are respectively disposed on both sides of a bridging component 113 extending from the respective core component 112.

[0130] According to an embodiment, the housing 30 may include resin surrounding at least a portion of the rotor core 100 and each of the plurality of magnets 20.

[0131] According to embodiments of the present disclosure, a rotor 1 may include a shaft 10, a plurality of magnets 20, a housing 30', and a rotor core 300. The rotor core 300 may include a through-hole 301 into which the shaft 10 is inserted, a plurality of first core layers 310, and a plurality of second layers 320. The first core layers 310 may include a plurality of core components 311 spaced apart from each other in the circumferential direction of the through-hole 301. The first core layers 310 may include a plurality of bridging components 312, each bridging component 312 including a pair of stop protrusions 3121 and 3122, which protrude circumferentially from each side of the outer end 311a of each of the plurality of core components 311 and bend toward the outer end.

[0132] According to an embodiment, a pair of stop protrusions 3121 and 3122 can be bent to be inclined relative to the core member 311.

[0133] According to the embodiment, the plurality of first core components 311 of the first core layer 310 may be a plurality of first core components 311, and the plurality of second core layers 121 may include a plurality of second core components 121 that are not connected to the plurality of bridging components 312.

[0134] According to an embodiment, a plurality of first core layers 310 and a plurality of second core layers 120 may be stacked alternately in the vertical direction.

[0135] According to an embodiment, the stop protrusions 3121 and 3122 protruding from each side of the outer end 311a of one of the plurality of core components 311 can be spaced apart from the stop protrusions 3121 and 3122 protruding from one side of the outer end 311a of the other core components 311 adjacent to the one core component 311.

[0136] According to an embodiment, the housing 30 may include resin surrounding at least a portion of the rotor core 300 and each of the plurality of magnets 20.

[0137] A method for manufacturing a rotor 1 according to an embodiment of the present disclosure, the rotor 1 including a shaft 10, a plurality of magnets 20, a housing 30 or 30', and a rotor core 100 or 300, may include: forming the rotor core 100a or 300a (1110) by stacking a first core layer 110a or 310a including a plurality of bridging components 113a or 312a and a second core layer 120 not including the plurality of bridging components 113a or 312a. The method for manufacturing the rotor 1 may include placing the rotor core 100a or 300a on a lower die 210. The method for manufacturing the rotor 1 may include mounting a plurality of magnets 20 on the rotor core 100a or 300a (1130). The method for manufacturing the rotor 1 may include stamping the plurality of bridging components 113a or 312a of the first core layer 110a or 310a by pressing down an upper die 220 having a stamping component 222 (1140).

[0138] According to an embodiment, a method for manufacturing rotor 1 may include coupling rotor core 100a or 300a to shaft 10 (1120) by inserting shaft 10 into through hole 101 or 301 of rotor core 100a or 300a.

[0139] According to an embodiment, a method for manufacturing rotor 1 may include injecting resin into molding equipment 210 and 220 and curing it to form a housing surrounding at least a portion of rotor core 100 or 300.

[0140] According to an embodiment, multiple bridging components 113a or 312a can be bent toward the first core layer 110a or 310a by pressing down the upper die 220.

[0141] According to an embodiment, the first core layer 110a may include a base component 111 and a plurality of core components 112, the plurality of core components 112 being connected to the base component 111 respectively through a corresponding bridging component 113a among a plurality of bridging components 113a, and the base component 111 and the plurality of core components 112 may be separated from each other by pressing down the upper mold 220.

[0142] According to an embodiment, the first core layer 310a may include a plurality of core components 311 connected to each other by a plurality of bridging components 312a, and the plurality of core components 311 may be separated from each other by pressing down the upper mold 220.

Claims

1. A rotor (1), comprising: Axis (10); Multiple magnets (20); Casing (30); as well as The rotor core (100) includes multiple first core layers (110) and multiple second core layers (120). The first core layer (110) includes: The base component (111) through which the shaft (10) passes. Multiple core components (112) are spaced apart from each other along the circumferential direction of the base component (111), and A plurality of bridging components (113, 113') are configured such that each of the plurality of bridging components (113, 113') extends from a corresponding core component of the plurality of core components (112) toward the base component (111) and bends toward the corresponding core component (112).

2. The rotor according to claim 1, wherein Each of the plurality of bridging components (113) is bent vertically relative to the corresponding core component (112).

3. The rotor according to claim 1, wherein Each of the plurality of bridging components (113') is bent to be inclined relative to the corresponding core component (112).

4. The rotor according to any one of claims 1 to 3, wherein The plurality of core components (112) of the first core layer (110) are a plurality of first core components (112), and The second core layer (120) includes a plurality of second core components (121) that are not connected to the plurality of bridging components (113, 113').

5. The rotor according to any one of claims 1 to 4, wherein, The plurality of first core layers (110) and the plurality of second core layers (120) are stacked alternately in the vertical direction.

6. The rotor according to any one of claims 1 to 5, wherein Each of the plurality of core components (112) includes a pair of curved grooves (1122) respectively disposed on both sides of the bridging component (113) extending from the respective core component (112).

7. A rotor (1), comprising: Axis (10); Multiple magnets (20); Housing (30'); as well as Rotor core (300), comprising: The through hole (301) into which the shaft (10) is inserted. Multiple first core layers (310), and Multiple second core layers (120). The first core layer (310) includes: Multiple core components (311) are spaced apart from each other along the circumferential direction of the through hole (301), and Multiple bridging components (312) include pairs of stop protrusions (3121, 3122) that protrude circumferentially from each side of the outer end of each of the multiple core components (311) and bend toward the outer end.

8. The rotor according to claim 7, wherein The paired stop protrusions (3121, 3122) are bent to be inclined relative to the core component (311).

9. The rotor according to claim 7 or 8, wherein The plurality of core components (311) of the first core layer (310) are a plurality of first core components (311), and The second core layer (120) includes a plurality of second core components (121) that are not connected to the plurality of bridging components (312).

10. The rotor according to any one of claims 7 to 9, wherein The plurality of first core layers (310) and the plurality of second core layers (120) are stacked alternately in the vertical direction.

11. The rotor according to any one of claims 7 to 10, wherein The stop protrusions (3121, 3122) protruding from each side of the outer end of one of the plurality of core components (311) are spaced apart from the stop protrusions (3121, 3122) protruding from each side of the outer end of the other core components (311) adjacent to the one core component (311).

12. A method of manufacturing a rotor (1), said rotor (1) comprising a shaft (10), a plurality of magnets (20), a housing (30, 30'), and a rotor core (100, 300), said method comprising: The rotor core (100a, 300a) (1110) is formed by stacking a first core layer (110a, 310a) including multiple bridging components (113a, 312a) and a second core layer (120) excluding the multiple bridging components (113a, 312a). The rotor cores (100a, 300a) are placed on the lower mold (210); The plurality of magnets (30) are mounted on the rotor core (100a, 300a) (1130); and The upper die (220) with a stamping component (222) is pressed down to stamp the plurality of bridging components (113a, 312a) (1140) of the first core layer (110a, 310a).

13. The method of claim 12, wherein By pressing down the upper mold (220), the plurality of bridging components (113a, 312a) are bent toward the first core layer (110a, 310a).

14. The method according to claim 12 or 13, wherein The first core layer (110a) includes a base component (111) and a plurality of core components (112), wherein the plurality of core components (112) are respectively connected to the base component (111) through a corresponding bridging component (113a) among the plurality of bridging components (113a), and By pressing down the upper mold (220), the base component (111) and the plurality of iron core components (112) are separated from each other.

15. The method according to claim 12 or 13, wherein The first core layer (310a) includes a plurality of core components (311) connected to each other via the plurality of bridging components (312a), and By pressing down the upper mold (220), the plurality of iron core components (311) are separated from each other.

Images