Injection molded magnet assembly for electric motor

Abstract

This utility model discloses an injection-molded magnet assembly for an electric motor, belonging to the technical field of magnet assembly. It includes an injection-molded outer shell and a magnetic housing, with a positioning hole inside the bottom wall of the injection-molded outer shell. The beneficial effects of this utility model are that it features a detachable magnetic housing and magnets. The positioning hole inside the bottom wall of the injection-molded outer shell provides alignment support for the magnetic housing. The magnetic housing is composed of multiple circular magnets arranged in a ring array, with a positioning post fixed at the bottom, inserted into the positioning hole of the injection-molded outer shell for positioning and fixation. The magnets are fixedly installed inside the magnetic housing, providing a magnetic field. The two outer walls of the magnetic housing are in contact with each other, enhancing the stability and strength of the overall structure. The injection-molded outer shell is installed on the outside of the magnetic housing through an injection molding process, forming a tight whole. A limit frame is provided on one side wall of the magnetic housing, with hexagonal bolts installed inside, which can further fix the injection-molded outer shell, ensuring the stability of the assembly.

Description

Technical Field

[0001] This utility model relates to the field of magnet assembly technology, specifically an injection-molded magnet assembly for an electric motor. Background Technology

[0002] An electric motor typically consists of a stator fixed to a housing and a rotor movable relative to the stator. For example, the rotor can be supported so that it can rotate relative to the stator or move linearly relative to the stator. Electric motors are classified as electromechanical energy converters and can be used as electric motors or generators.

[0003] To meet the demands of low-speed, high-torque operation in various work environments, one of two methods is typically employed: either reducing the operating frequency of the power supply to the asynchronous motor, or increasing the number of poles in the asynchronous motor. However, low-frequency power supply requires expensive power electronics, increasing costs and potentially affecting motor stability. Conversely, while increasing the number of poles lowers the required power supply frequency, it increases leakage inductance, leading to a decrease in the motor's power factor. Although permanent magnet motors do not require electrical excitation, increasing the number of permanent magnet poles also increases leakage flux, reducing the motor's effective output power. Since motor torque is proportional to its size, obtaining high torque necessitates a larger motor. Such large motors not only occupy more space and use more materials, increasing manufacturing costs, but also pose greater challenges for mechanical installation and maintenance. Therefore, to achieve speed and torque matching between the motor and load, mechanical transmission mechanisms such as gearboxes are often used in industry. However, these mechanical transmission mechanisms also have inherent drawbacks, such as vibration, noise, and metal fatigue, which significantly reduce the overall stability of the motor system and increase maintenance costs and complexity. Utility Model Content

[0004] To address the problems mentioned in the background section, this invention provides an injection-molded magnet assembly for an electric motor. This assembly addresses the common practice of using one of two methods to meet the demands of low-speed, high-torque operation: either reducing the power supply frequency or increasing the number of poles. However, low-frequency power supply requires expensive power electronics, increasing costs and potentially affecting motor stability. Conversely, while increasing the number of poles lowers the required power supply frequency, it increases leakage inductance, leading to a decrease in power factor. Although permanent magnet motors do not require electrical excitation, increasing the number of poles still increases leakage flux, reducing effective output power. Since motor torque is proportional to its size, higher torque requires larger motors. Such large motors not only occupy more space and use more materials, increasing manufacturing costs, but also pose greater challenges for mechanical installation and maintenance. Therefore, mechanical transmission mechanisms such as gearboxes are often used in industry to achieve speed and torque matching between the motor and the load. However, these mechanical transmission mechanisms also have some inherent defects, such as vibration, noise and metal fatigue, which can significantly reduce the overall stability of the motor working system and increase the maintenance cost and difficulty of the system.

[0005] The technical solution of this utility model is: an injection-molded magnet assembly for an electric motor, comprising an injection-molded outer shell and a magnetic housing. The bottom wall of the injection-molded outer shell has a positioning hole. A positioning post is fixedly installed at the bottom of the magnetic housing. The positioning post is movably inserted into the positioning hole. The magnet is fixedly embedded inside the magnetic housing. The magnetic housing is evenly distributed in a ring array, and the outer walls on both sides of the magnetic housing are in contact with each other. The injection-molded outer shell is installed on the outside of the magnetic housing by injection molding. A limit frame is provided on one side wall of the magnetic housing. A hexagonal bolt is installed through the limit frame and extends into the side wall of the injection-molded outer shell.

[0006] Furthermore, one side of the injection-molded shell is set as an opening, and the injection-molded shell is a regular polygonal body with symmetrical arrangement on both sides.

[0007] Furthermore, both the magnet and the magnetic shell are trapezoidal in shape, with the inner length being less than the outer length.

[0008] Furthermore, one side of the outer wall of the magnet is exposed, while the remaining surface is enclosed inside the magnetic shell, and the magnetic poles of the two symmetrical magnets are in opposite directions.

[0009] Furthermore, the magnet is a neodymium iron boron magnet, and the magnetic shell is a magnetically attached metal shell.

[0010] Furthermore, the injection-molded housing is made of insulating rubber.

[0011] This utility model provides an improved injection-molded magnet assembly for an electric motor, which has the following improvements and advantages compared with the prior art:

[0012] The injection-molded housing features a detachable magnetic shell and magnets. Positioning holes are located inside the bottom wall of the shell to provide alignment support. The magnetic shell consists of multiple circular magnets arranged in a ring array. A positioning post is fixed at the bottom and inserted into the positioning holes of the injection-molded housing for positioning and fixation. The magnets are fixedly installed inside the magnetic shell to provide a magnetic field. The two outer walls of the magnetic shell are in contact with each other, enhancing the stability and strength of the overall structure. The injection-molded housing is installed on the outside of the magnetic shell through injection molding, forming a tight whole. A limit frame is provided on one side wall of the magnetic shell, with hexagonal bolts installed inside. These bolts can further fix the injection-molded housing, ensuring the stability of the component. The injection-molded housing effectively protects and fixes the magnetic shell. The cooperation of the positioning post and positioning holes ensures precise installation of the component. The contacting sides of the magnetic shell improve structural strength, the magnets provide a stable magnetic field, and the hexagonal bolts enhance the overall tightness and stability. Attached Figure Description

[0013] The present invention will be further explained below with reference to the accompanying drawings and embodiments:

[0014] Figure 1 This is a three-dimensional assembly diagram of the present invention;

[0015] Figure 2 This is a three-dimensional schematic diagram of the present invention;

[0016] Figure 3 This is a three-dimensional schematic diagram of the magnet installation of this utility model;

[0017] Figure 4 This is a cross-sectional view of the injection-molded shell of this utility model;

[0018] Explanation of reference numerals in the attached diagram: 1. Injection-molded outer shell; 2. Positioning post; 3. Magnetic shell; 4. Magnet; 5. Limiting frame; 6. Hex bolt. Detailed Implementation

[0019] The following will be combined with the appendix Figures 1 to 4 This utility model will be described in detail, and the technical solutions in the embodiments of this utility model will be clearly and completely described. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of this utility model.

[0020] This utility model provides an improved injection-molded magnet assembly for an electric motor, such as... Figure 1-4 As shown in the figure, the device includes an injection-molded outer shell 1 and a magnetic shell 3. The bottom wall of the injection-molded outer shell 1 has a positioning hole. A positioning post 2 is fixedly installed at the bottom of the magnetic shell 3, and the positioning post 2 is movably inserted into the positioning hole. A magnet 4 is fixedly embedded inside the magnetic shell 3. The magnetic shell 3 is evenly distributed in a ring array, and the outer walls of both sides of the magnetic shell 3 are in contact with each other. The injection-molded outer shell 1 is installed on the outside of the magnetic shell 3 by injection molding. A limit frame 5 is provided on one side wall of the magnetic shell 3. A hexagonal bolt 6 is installed through the limit frame 5 and extends into the side wall of the injection-molded outer shell 1. The device features a detachable magnetic shell 3 and magnets 4. The positioning hole in the bottom wall of the injection-molded outer shell 1 provides alignment support for the magnetic shell 3. The magnetic shell 3 is composed of multiple circular magnets 4 distributed in a ring array, and a magnet 4 is fixed at the bottom. A positioning post 2 is inserted into the positioning hole of the injection-molded shell 1 to achieve positioning and fixation. The magnet 4 is fixedly installed inside the magnetic shell 3 to provide a magnetic field. The two outer walls of the magnetic shell 3 are in contact with each other, which can enhance the stability and strength of the overall structure. The injection-molded shell 1 is installed on the outside of the magnetic shell 3 through the injection molding process to form a tight whole. A limit frame 5 is set on one side wall of the magnetic shell 3, and hexagonal bolts 6 are installed inside. The injection-molded shell 1 can be further fixed by the bolts to ensure the stability of the component. The injection-molded shell 1 effectively protects and fixes the magnetic shell 3. The cooperation of the positioning post 2 and the positioning hole ensures the precise installation of the component. The contacting sides of the magnetic shell 3 improve the structural strength. The magnet 4 provides a stable magnetic field, while the hexagonal bolts 6 enhance the overall tightness and stability.

[0021] One side of the injection-molded housing 1 is set as an opening, and the injection-molded housing 1 is a regular polygonal body with symmetrical arrangement on both sides. The magnet 4 and the magnetic shell 3 are both trapezoidal, and the inner length is less than the outer length. One side of the outer wall of the magnet 4 is exposed, and the other side is wrapped inside the magnetic shell 3. The magnetic poles of the two symmetrical magnets 4 are opposite. The magnet 4 is a neodymium iron boron magnet. The magnetic shell 3 is a magnetic metal shell. The injection-molded housing 1 is made of insulating rubber. The magnetic shells 3 are arranged in a ring array and are in contact with each other, which helps to form a uniform magnetic field. The injection-molded housing 1 is a regular polygonal body, and the opening design facilitates the installation and maintenance of the magnet 4. Overall, all components work together. The injection-molded housing 1 fixes the magnetic housing 3 and the magnet 4. The magnetic field generated by the magnet 4 is concentrated by the magnetic housing 3, and then protected and supported by the injection-molded housing 1, forming a high-efficiency magnet 4 assembly. It is suitable for high-efficiency magnetic energy conversion and stable operation of motors. The injection-molded housing 1 is made of insulating rubber material, which provides insulation and mechanical protection. The magnetic housing 3 is a magnetic metal housing, which is used to concentrate and enhance the magnetic field. The magnet 4 is a neodymium iron boron magnet, which generates a strong magnetic field. The trapezoidal design makes the installation of the magnet 4 more stable and less likely to fall off.

[0022] All standard parts used in this utility model can be purchased from the market, and irregular parts can be customized according to the description and drawings. The specific connection methods of each part adopt conventional methods such as bolts, rivets, and welding that are mature in the prior art. The machinery, parts and equipment adopt conventional models in the prior art. In addition, the circuit connection adopts conventional connection methods in the prior art, which will not be described in detail here. The contents not described in detail in this specification belong to the prior art known to those skilled in the art.

[0023] The above description of the disclosed embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An injection molded magnet assembly for an electric motor comprising an injection molded housing (1) and a magnetically concentrating shell (3), characterized in that: The bottom wall of the injection-molded shell (1) has a positioning hole. The bottom of the magnetic shell (3) is fixedly installed with a positioning post (2). The positioning post (2) is movably inserted into the positioning hole. The magnet (4) is fixedly embedded in the inside of the magnetic shell (3). The magnetic shell (3) is evenly distributed in a ring array, and the outer walls on both sides of the magnetic shell (3) are in contact with each other. The injection-molded shell (1) is installed on the outside of the magnetic shell (3) by injection molding. A limit frame (5) is provided on one side wall of the magnetic shell (3). A hexagonal bolt (6) is installed through the inside of the limit frame (5) and extends into the inside of the side wall of the injection-molded shell (1).

2. The injection molded magnet assembly for an electric motor as defined in claim 1, wherein: The injection-molded shell (1) has an opening on one side, and the injection-molded shell (1) is a regular polygonal body with symmetrical arrangement on both sides.

3. The injection molded magnet assembly for an electric motor as defined in claim 1, wherein: Both the magnet (4) and the magnetic shell (3) are trapezoidal in shape, and the inner length is less than the outer length.

4. The injection molded magnet assembly for an electric motor of claim 1, wherein: One side of the outer wall of the magnet (4) is exposed, while the other side is enclosed inside the magnetic shell (3). The magnetic poles of the two symmetrical magnets (4) are opposite in direction.

5. The injection molded magnet assembly for an electric motor as defined in claim 1, wherein: The magnet (4) is a neodymium iron boron magnet, and the magnetic shell (3) is a magnetic metal shell.

6. The injection-molded magnet assembly for an electric motor as described in claim 1, characterized in that: The injection-molded outer shell (1) is made of insulating rubber.

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