Compact stator core and brushless motor comprising same

Abstract

The utility model discloses a compact stator core and a brushless motor comprising the same, the compact stator core comprises an annular yoke part and a plurality of tooth parts extending from the annular yoke part to the axis of the annular yoke part, and each tooth part comprises a pole body with one end connected with the annular yoke part and a pole shoe connected with the other end of the pole body; the annular yoke part is provided with a plurality of terminal holes and wire clamping tables, the wire clamping tables are arranged on the radial outer sides of the tooth parts in a one-to-one correspondence mode, and in the stator iron core after injection molding, the upper end faces of the wire clamping tables, the annular yoke part and the end of the pole body are located on the same injection molding face. According to the utility model, the annular yoke part and the end part of the pole body are positioned on the same injection molding surface, and the wire clamping table for clamping the enameled wire in the wiring groove and the annular yoke part are positioned on the same plane, so that the axial height of the stator core is reduced under the condition that the axial height of the pole body is not changed, the miniaturization of the stator assembly and the brushless motor is realized, and the cost is reduced. And the device is suitable for occasions with high space requirements.

Description

Technical Field

[0001] The utility model relates to the technical field of motor design, in particular to a compact stator core and a brushless motor including the same, which are mainly used for an automotive intake grille adjustment actuator. Background Art

[0002] The main function of an automotive intake grille is to provide an intake passage for an automotive engine or battery pack to facilitate timely heat dissipation of the vehicle. With the popularization of automotive automation, more and more components need to be installed in a vehicle, which requires the design of each component to be as compact as possible. For the stator core in an automotive intake grille adjustment actuator, in order to separate the lead-in and lead-out enameled wires of different winding slots and avoid the enameled wires from being messy, the yoke is usually made higher than the pole body in a traditional stator core, so as to design a wire threading and enameled wire fixing structure on the yoke. However, this will increase the axial dimension of the stator core, thereby increasing the overall height of the stator assembly and making it inapplicable to occasions with strict structural compactness requirements.

[0003] In addition, the wire routing groove in the existing stator core is designed on the upper side of the stator assembly and cooperates with the protruding yoke to form a wire routing groove, and the wire routing groove itself occupies a certain axial space, further increasing the axial dimension of the stator core.

[0004] In summary, how to design a stator core that can reduce the axial dimension and is applicable to occasions with strict structural compactness requirements is a technical problem that needs to be solved currently. Summary of the Utility Model

[0005] In order to solve the technical problem that the yoke in the stator core of the existing technology is higher than the pole body, resulting in an increase in its axial dimension, the utility model provides a compact stator core and a brushless motor including the same to solve the above problems.

[0006] The utility model provides a compact stator core, including an annular yoke and a plurality of tooth portions extending from the annular yoke towards its axis. Each tooth portion includes a pole body connected to the annular yoke at one end and a pole shoe connected to the other end of the pole body. The annular yoke is provided with a plurality of terminal holes and wire clamping platforms, and the wire clamping platforms are respectively arranged on the radial outer sides of each tooth portion. In the stator core after injection molding, the upper end surfaces of the wire clamping platforms, the end surface of the annular yoke, and the end surface of the pole body are in the same injection molding surface.

[0007] Furthermore, an insulating injection molding material is injection molded on the radial outer peripheral surface of the annular yoke.

[0008] Furthermore, a wire routing groove is arranged on the circumferential outer side of one end of the annular yoke, and the wire clamping platform protrudes radially outward from the end of the annular yoke.

[0009] Further, one end face of the annular yoke portion has a wire routing groove that is axially recessed, and the wire clamping platform is located above the wire routing groove.

[0010] Further, the axial height of the wire routing groove is 1 mm to 3 mm.

[0011] Further, both axial ends of each pole shoe have baffles that protrude from the pole body.

[0012] Further, the wire routing groove surrounds the entire outer circumference of the annular yoke portion.

[0013] Further, the terminal hole axially penetrates through both ends of the annular yoke portion.

[0014] The present utility model also provides a brushless motor, including a stator assembly, a wiring terminal, and a circuit board. The stator assembly includes the compact stator core described above, a skeleton assembled with the compact stator core, and enameled wires wound around the skeleton. The wiring terminal is inserted into the terminal hole of the compact stator core, and the leads of the enameled wires and the leads of the circuit board are both connected to the wiring terminal.

[0015] Further, the terminal hole axially penetrates through both ends of the annular yoke portion, and the leads of the enameled wires and the leads of the circuit board are respectively connected to both ends of the wiring terminal.

[0016] Further, the compact stator core and the skeleton are integrally injection molded.

[0017] The beneficial effects of the present utility model are as follows:

[0018] (1) The present utility model makes the end of the annular yoke portion and the end of the pole body on the same injection surface, and at the same time, the wire clamping platform for clamping the enameled wire inside the wire routing groove is on the same plane as the annular yoke portion. Thus, without changing the axial height of the pole body, the axial height of the stator core is reduced, realizing the miniaturization of the stator assembly and the brushless motor, and being applicable to occasions with high space requirements.

[0019] (2) The present utility model arranges the wire routing groove on the outer peripheral surface of the annular yoke portion, making it located below the end face of the stator core, which can not only reduce the axial height of the stator core but also avoid the terminals. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The following further illustrates the present utility model in conjunction with the drawings and embodiments.

[0021] Figure 1 is a perspective view of a specific embodiment of the compact stator core described in the present utility model;

[0022] Figure 2 is a front view of a specific embodiment of the compact stator core described in the present utility model;

[0023] Figure 3 is Figure 2 the sectional view taken along line A-A;

[0024] Figure 4 is the schematic diagram of the enameled wire winding in the present utility model;

[0025] Figure 5 is the schematic assembly diagram of the stator assembly and the circuit board in the present utility model.

[0026] In the figure, 1. annular yoke, 2. tooth part, 201. pole body, 202. pole shoe, 203. baffle, 3. terminal hole, 4. wire clamping platform, 5. terminal, 6. circuit board, 7. enameled wire, 8. wire routing groove, 9. stator core. Detailed implementation manners

[0027] The embodiments of the present utility model will be described in detail below. The examples of the embodiments are shown in the drawings, where the same or similar reference numerals represent the same or similar elements or elements with the same or similar functions from beginning to end. The embodiments described below by referring to the drawings are exemplary and are only used to explain the present utility model and should not be construed as a limitation to the present utility model.

[0028] An automotive intake grille adjustment actuator generally preferably uses a DC brushless motor. The DC brushless motor usually includes a stator assembly, a rotor assembly, a circuit board 6, and a housing assembly, as Figure 5 shown. The stator assembly includes a coil skeleton, a terminal 5, and an enameled wire 7 wound around the coil skeleton. The coil skeleton is composed of a stator core 9 and a skeleton wrapped outside the stator core 9. The skeleton plays an insulating and protective role for the stator core 9. The skeleton and the stator core 9 can be integrally injection-molded.

[0029] The present utility model aims to provide a stator assembly with a lower axial height, and improves the structure of the stator core 9. The specific structure is as follows:

[0030] As Figures 1-3As shown in the figure, a compact stator core includes an annular yoke portion 1 and a plurality of tooth portions 2 extending from the annular yoke portion 1 towards its axis. The tooth portion 2 includes a pole body 201 connected to the annular yoke portion 1 at one end and a pole shoe 202 connected to the other end of the pole body 201. The tooth portion 2 separates the winding grooves of adjacent coil skeletons. Since the surface of the stator core 9 in contact with the enameled wire 7 is usually located on the end face and inner circumferential surface of the annular yoke portion 1 and the tooth portion 2, the skeleton is injection-molded on these structural surfaces. In the present utility model, the end of the annular yoke portion 1 and the pole body 201 are on the same injection surface; the annular yoke portion 1 is provided with a plurality of terminal holes 3 and wire clamping platforms 4. The wire clamping platforms 4 are arranged on the radial outer side of each tooth portion 2 one by one, and the upper end surface of the wire clamping platform 4 is on the same plane as the annular yoke portion 1. That is, the upper end surface of the wire clamping platform 4, the end face of the annular yoke portion 1, and the end face of the pole body 201 in the injection-molded stator core are on the same injection surface.

[0031] In the prior art, the end face of the annular yoke portion 1 opposite to the pole body 201 is higher than the end face of the pole body 201, and the enameled wire 7 is wound around the protruding part on the annular yoke portion 1 and wound in different winding grooves. In the present utility model, the annular yoke portion 1 and the pole body 201 are on the same injection surface, and at the same time, a wire clamping platform 4 is specifically provided on the annular yoke portion 1. As Figure 4 shown, after the enameled wire 7 is wound outside each tooth portion 2, it is fixed by the wire clamping platform 4 on the radial outer side and then transferred to other tooth portions 2 through the wire routing groove 8, so that the enameled wire 7 is arranged according to the specified route, and the wire clamping platform 4 does not exceed the ends of the annular yoke portion 1 and the pole body 201. Thus, without changing the axial height of the pole body 201, the axial height of the stator core 9 is reduced, miniaturization is achieved, and the space inside the actuator is saved.

[0032] In order to isolate the metal stator core 9 from the outside and increase the oxidation resistance of the stator core 9, the present utility model preferably injects an insulating injection molding material on the radial outer circumferential surface of the annular yoke portion 1.

[0033] The wire clamping platform 4 is used to clamp the enameled wire 7 in the wire routing groove 8, and the wire routing groove 8 can be arranged in two ways. The first way is to be arranged on one end face of the annular yoke portion 1 and axially recessed downward, and the wire clamping platform 4 is located above the wire routing groove 8, so that the wire clamping platform 4 does not protrude from the surface of the annular yoke portion 1.

[0034] Another way, which is also the preferred way of the present utility model, as Figure 1 and Figure 3 shown, the wire routing groove 8 is arranged on the circumferential outer side of one end of the annular yoke portion 1, and the wire clamping platform 4 protrudes radially outward from the end of the annular yoke portion 1. This can ensure the flatness of the end face of the annular yoke portion 1, facilitate the injection molding of the skeleton, and at the same time can make way for the terminals. The wire routing groove 8 is wound around the entire outer circumference of the annular yoke portion 1, which is convenient for processing. The axial height of the wire routing groove 8 is preferably 1 mm to 3 mm, which can not only accommodate the enameled wire 7 but also ensure the strength of the stator core 9.

[0035] The terminal hole 3 axially penetrates through both ends of the annular yoke portion 1, and a wiring terminal 5 is installed at the terminal hole 3, and the wiring terminal 5 protrudes from the end face of the annular yoke portion 1.

[0036] Preferably, baffles 203 protruding from the pole body 201 are provided at both axial ends of each pole shoe 202, and the baffles 203 are used to limit the enameled wire 7 to prevent the enameled wire 7 from disengaging inward from the tooth portion 2.

[0037] In a further preferred embodiment of the brushless motor of the present invention, as Figure 3 and Figure 5 shown, the terminal hole 3 axially penetrates through both ends of the annular yoke portion 1, and the leads of the enameled wire 7 and the leads of the circuit board 6 are respectively connected to both ends of the wiring terminal 5.

[0038] In the prior art, the enameled wire and the circuit board are connected to the same end of the wiring terminal, which will result in a complex processing technology and low assembly efficiency. In this embodiment, the connection work of the enameled wire 7 and the circuit board 6 can be carried out at both ends of the wiring terminal 5 respectively, and the two works do not interfere with each other, which is not only convenient for assembly, but also can realize synchronous work and improve production efficiency.

[0039] The wiring terminal 5 is preferably a fish-eye terminal, and the elastic crimping of the fish-eye terminal replaces the traditional welding process to further improve the assembly efficiency.

[0040] In the description of the present invention, it should be understood that the orientation or positional relationship indicated by the terms "center", "inner", "outer", "axial", etc. is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention.

[0041] In addition, the terms "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying relative importance. In the description of the present invention, it should be noted that unless otherwise clearly defined and limited, the terms "connected" and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations. In addition, in the description of the present invention, unless otherwise stated, the meaning of "plurality" is two or more.

[0042] In this specification, the schematic expressions of the terms do not necessarily refer to the same embodiment. Moreover, the specific features, structures, materials, or characteristics described can be combined in a suitable manner in any one or more embodiments.

[0043] Inspired by the above ideal embodiments of the present utility model, through the above description, relevant staff can completely make various changes and modifications without departing from the technical idea of the present utility model. The technical scope of the present utility model is not limited to the content in the specification, and its technical scope must be determined according to the scope of the claims.

Claims

1. A compact stator core, characterized in that: The stator core is integrally injection molded and comprises an annular yoke (1) and a plurality of teeth (2) extending from the annular yoke (1) toward the axis thereof, wherein the teeth (2) comprises a pole body (201) connected to the annular yoke (1) at one end and a pole shoe (202) connected to the other end of the pole body (201); The annular yoke (1) is provided with a plurality of terminal holes (3) and wire clamping platforms (4), the wire clamping platforms (4) being arranged one by one on the radial outer side of each tooth portion (2), and in the stator core after injection molding, the upper end surface of the wire clamping platform (4), the end surface of the annular yoke (1) and the end surface of the pole body (201) are located on the same injection molding surface.

2. The compact stator core according to claim 1, characterized in that: The radial outer peripheral surface of the annular yoke (1) is injection molded with insulating injection molding material.

3. The compact stator core according to claim 1, characterized in that: A wire routing groove (8) is provided on the circumferential outer side of one end of the annular yoke (1), and the wire clamping platform (4) protrudes radially outward from the end of the annular yoke (1).

4. The compact stator core according to claim 1, characterized in that: One end surface of the annular yoke (1) has an axially recessed wire routing groove (8), and the wire clamping platform (4) is located above the wire routing groove (8).

5. The compact stator core according to claim 3, characterized in that: The axial height of the wiring groove (8) is 1 mm to 3 mm.

6. The compact stator core according to claim 1, characterized in that: Each of the pole shoes (202) has baffles (203) protruding from the pole body (201) at both axial ends.

7. The compact stator core according to claim 3, characterized in that: The wiring groove (8) completely surrounds the outer circumference of the annular yoke (1).

8. A brushless motor, characterized in that: The invention comprises a stator assembly, a terminal block (5) and a circuit board (6), wherein the stator assembly comprises the compact stator core according to any one of claims 1 to 7, a frame assembled with the compact stator core and an enameled wire (7) wound on the frame, the terminal block (5) is inserted into the terminal hole (3) of the compact stator core, and the lead wires of the enameled wire (7) and the lead wires of the circuit board (6) are both connected to the terminal block (5).

9. The brushless motor according to claim 8, characterized in that: The terminal hole (3) axially penetrates through both ends of the annular yoke (1), and the lead wire of the enameled wire (7) and the lead wire of the circuit board (6) are respectively connected to both ends of the connection terminal (5).

10. The brushless motor according to claim 8, characterized in that: The compact stator core and the frame are integrally injection molded.

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