Plastic package brushless DC motor

Abstract

The utility model discloses a plastic package brushless DC motor, it includes rear end cover, wave washer, 608 ball bearing, open baffle, rotor component, insulating gasket, power cord and BMC stator assembly. The rear end cover adopts riveting installation of metal material, reduces resonance noise, the wave washer optimizes pressure distribution, promotes operating stability, the BMC stator assembly integrative injection moulding has excellent insulation fireproof and moistureproof performance. Through optimizing structure design and material selection, the application realizes high efficiency, low cost, low noise and good insulation performance, especially suitable for washing and drying integrated machine and other high frequency vibration working condition, significantly improves user experience and satisfies market demand.

Description

Technical Field

[0001] This utility model relates to the field of motor technology, and in particular to a plastic-encapsulated brushless DC motor. Background Technology

[0002] In the home appliance industry, especially in washer-dryer combos, the motor is a core component, and its performance directly affects the equipment's operating efficiency and user experience. Currently, shaded-pole motors are widely used in economy washer-dryer combos due to their simple structure and low cost. However, shaded-pole motors have significant technical drawbacks, such as an efficiency of only 25% and low rotational speed, resulting in longer drying times and a poorer user experience. Furthermore, shaded-pole motors are inadequate in terms of insulation, fire resistance, and moisture resistance, and tend to generate high noise levels during operation, making it difficult to meet the modern home appliance demands for high efficiency, low noise, and reliability.

[0003] In contrast, BMC capacitor motors, by employing aluminum wire windings and a BMC-coated stator, achieve an efficiency increase of up to 47%, significantly improving speed under fan load and thus drastically reducing drying time. Simultaneously, the application of BMC material endows the motor with excellent insulation, fire resistance, and moisture resistance, effectively reducing operating noise. However, existing BMC capacitor motors still have room for improvement under high-frequency vibration conditions. For example, the casing is susceptible to deformation due to electromagnetic forces and external installation stress, which can affect the motor's stability and lifespan. Furthermore, traditional motor assembly methods may pose a risk of loosening, further limiting their application in harsh operating conditions.

[0004] On the other hand, the design of the impeller used with the motor also faces technical challenges. Aluminum alloy impellers are prone to lint accumulation during use. Excessive lint can prevent the impeller from blowing air properly, and may even cause problems such as dry burning of the heating element and damage to the fan, ultimately leading to equipment malfunction. Although new plastic impellers have reduced the possibility of lint accumulation through optimized blade structure angle design, ensuring efficient and coordinated operation of the impeller and motor remains a problem that needs to be solved. Therefore, developing a motor that combines high efficiency, high reliability, low noise, and excellent assembly process has become a pressing technical challenge for the industry. Utility Model Content

[0005] The purpose of this utility model is to provide a plastic-encapsulated brushless DC motor that solves the problems mentioned in the background art.

[0006] This utility model is implemented as follows: a plastic-encapsulated brushless DC motor includes a rear end cover, a wave washer, a 608 ball bearing, an open retaining ring, a rotor assembly, an insulating gasket, a power cord, and a BMC stator assembly. Wherein:

[0007] The rear end cover is located at the rear of the motor and is part of the motor housing. It is made of metal and installed by riveting. Furthermore, the rear end cover forms a rigid connection with the motor housing through riveting, thereby avoiding the risk of loosening under high-frequency vibration conditions and improving production efficiency and structural reliability. In particular, the design of the rear end cover also takes into account the need to reduce resonance noise; its material selection and geometry have been optimized to reduce acoustic noise during motor operation.

[0008] Furthermore, the corrugated washer is located between the rear end cover and the 608 ball bearing to provide preload and reduce axial movement of the bearing during operation. The corrugated washer achieves uniform pressure distribution through its corrugated design, thereby enhancing the buffering effect and improving the stability of motor operation. The elastic modulus of the corrugated washer is precisely calculated to ensure stable performance under different operating temperatures and load conditions.

[0009] Furthermore, the 608 ball bearings are located at both ends of the rotor assembly to support it and reduce frictional resistance during rotation. The 608 ball bearings feature a standard design that achieves good load-bearing capacity and wear resistance, while the clearance between them and the rotor assembly is precision-machined to ensure smooth motor operation. Specifically, the 608 ball bearings have an open retaining ring on their outer side to fix the bearing position and prevent axial movement. This open retaining ring is made of elastic metal material, and its open design facilitates installation and disassembly, while effectively locking the bearing position through radial elasticity.

[0010] Furthermore, the rotor component, located at the center of the motor, consists of a shaft and magnets, and rotates under the influence of the stator magnetic field to generate mechanical energy output. The magnets of the rotor component are fixed to the rotor shaft by an interference fit and are magnetized to obtain a uniform magnetic field distribution. In particular, the design of the rotor component also considers the optimization of rotational inertia, improving the dynamic response performance of the motor by adjusting the mass distribution and geometry of the magnets.

[0011] Furthermore, the insulating gasket is located between the rotor assembly and the BMC stator assembly to provide electrical insulation and prevent current from flowing through non-conductive paths. The insulating gasket is made of an insulating material with excellent pressure and temperature resistance, and its thickness is precisely calculated to meet the insulation requirements of the motor at rated and peak voltages. In particular, the surface of the insulating gasket undergoes special treatment to enhance its moisture resistance and anti-aging properties, thereby extending the service life of the motor.

[0012] Furthermore, the power cord extends from one side of the motor to connect to an external power source and provide power input to the motor. The conductor of the power cord employs a multi-strand stranded structure to improve flexibility and fatigue resistance, while the outer layer is covered with a high-temperature resistant and wear-resistant insulating material to adapt to the motor's operating environment. Specifically, the lead-out end of the power cord is sealed to the motor housing via injection molding, thereby preventing moisture and dust from entering the motor.

[0013] Furthermore, the BMC stator assembly is located within the motor housing, surrounding the rotor components, and is used to generate a magnetic field and drive the rotor to rotate. The BMC stator assembly is integrally injection molded from BMC material, possessing excellent insulation, fire resistance, and moisture resistance, effectively withstanding internal electromagnetic forces and external installation stresses, and preventing housing deformation. In particular, the windings of the BMC stator assembly utilize aluminum wire technology; by precisely controlling the number of turns and wire diameter, motor efficiency is improved while reducing costs.

[0014] The innovative points and specific implementation methods of this utility model include the following aspects:

[0015] S1. High-efficiency and energy-saving design: The BMC stator assembly achieves a motor efficiency of up to 47% through optimized winding design and magnetic field distribution, significantly higher than the 25% of traditional shaded-pole motors. Furthermore, the windings utilize aluminum wire technology, which further reduces costs compared to copper wire windings, while maintaining high performance through precise turn count and wire diameter design.

[0016] S2. Low-cost manufacturing: The one-piece injection molding process of the BMC stator assembly reduces the number of parts and assembly steps, thereby lowering production costs. In particular, the introduction of aluminum wire windings further reduces material costs, while optimizing the winding layout improves space utilization.

[0017] S3. Excellent insulation, fire resistance, and moisture resistance: The selection of the BMC material and the injection molding process ensure reliable operation of the stator assembly in complex working environments. Furthermore, the formulation of the BMC material has been optimized to improve its heat resistance and flame retardant properties, thereby meeting the safety requirements of the motor.

[0018] S4. Low-noise design: The riveting installation method of the rear end cover and the pressure distribution design of the wave gasket work together to significantly reduce resonance noise during motor operation. In particular, the rigid structure of the BMC stator assembly further reduces vibration transmission, thereby improving the user experience.

[0019] S5. Stable and reliable operation: The riveting installation method of the rear end cover and the locking design of the split retaining ring jointly ensure the stability and reliability of the motor under high-frequency vibration working conditions. Further, the precision machining and fit clearance control of the 608 ball bearing improve the operation accuracy and service life of the motor.

[0020] S6. Chip accumulation resistance design: The new plastic wind wheel matched with the motor reduces the possibility of lint adsorption by adjusting the angle of the blade structure. In particular, the surface of the wind wheel is specially treated to reduce the electrostatic effect, thereby further reducing the risk of lint accumulation.

[0021] The technical effects of the utility model are achieved through the above technical solutions: The plastic-sealed brushless DC motor realizes high efficiency, low cost, low noise and good insulation, fireproof and moisture-proof performance by optimizing the structural design and material selection, and is especially suitable for applications under high-frequency vibration working conditions such as washer-dryer all-in-one machines. Further, the high-efficiency energy-saving design and chip accumulation resistance design of the motor significantly improve the user experience, while meeting market demands through low-cost manufacturing processes. Brief Description of the Drawings

[0022] Figure 1 is a schematic diagram of the overall structure of the utility model;

[0023] Figure 2 is a partial cross-sectional view of the utility model, showing the assembly relationship of internal components.

[0024] The reference numerals in the drawings are as follows:

[0025] 1. Rear end cover; 2. Wave washer; 3. 608 ball bearing; 4. Split retaining ring; 5. Rotor component;

[0026] 6. 608 ball bearing; 7. Insulation gasket; 8. Power cord; 9. BMC stator assembly. Detailed Description of the Embodiments

[0027] The utility model provides a plastic-sealed brushless DC motor, whose structure and function are described in detail through Figure 1 and Figure 2 . Figure 1 shows the schematic diagram of the overall structure of the utility model, Figure 2 is a partial cross-sectional view, used to show the assembly relationship of internal components. The specific embodiments of the utility model are described in detail below with reference to the accompanying drawings.

[0028] As shown in Figure 1 and Figure 2As shown, the encapsulated brushless DC motor of this invention includes a rear end cover 1, a wave washer 2, a 608 ball bearing 3, an open retaining ring 4, a rotor assembly 5, an insulating gasket 7, a power cord 8, and a BMC stator assembly 9. These components, through precise design and optimized assembly, together achieve the motor's efficient operation and stable performance.

[0029] The rear end cover 1 is located at the rear of the motor and is part of the motor housing. It is made of metal and installed by riveting. The connection between the rear end cover 1 and the motor housing is formed into a rigid structure through riveting, thereby avoiding the risk of loosening under high-frequency vibration conditions. This connection method not only improves production efficiency but also enhances structural reliability. The design of the rear end cover 1 is optimized, and its material selection and geometry effectively reduce resonance noise. For example, the thickness and edge curvature of the rear end cover 1 are precisely calculated to reduce the generation of acoustic noise. In addition, the surface of the rear end cover 1 is polished, further reducing vibration noise caused by friction.

[0030] The corrugated washer 2 is located between the rear end cover 1 and the 608 ball bearing 3 to provide preload and reduce axial movement of the bearing during operation. The corrugated washer 2 achieves uniform pressure distribution through its corrugated design, thereby enhancing the buffering effect and improving the stability of motor operation. The elastic modulus of the corrugated washer 2 is precisely calculated to ensure stable performance under different operating temperatures and load conditions. For example, in high-temperature environments, the elasticity of the corrugated washer 2 will not decrease significantly, thus ensuring the normal operation of the bearing.

[0031] 608 ball bearings 3 are located at both ends of the rotor assembly 5, supporting the rotor assembly 5 and reducing frictional resistance during rotation. The 608 ball bearings 3 achieve good load-bearing capacity and wear resistance through a standard design, while the fit clearance with the rotor assembly 5 is precision-machined to ensure smooth motor operation. Specifically, the 608 ball bearings 3 have an open retaining ring 4 on their outer side to fix the bearing position and prevent axial movement. The open retaining ring 4 is made of elastic metal material, and its open design facilitates installation and disassembly, while effectively locking the bearing position through radial elasticity. This design prevents bearing displacement during high-speed operation, thereby improving the motor's operating accuracy.

[0032] The rotor assembly 5, located at the center of the motor, consists of a shaft and magnets. It rotates under the influence of the stator's magnetic field to generate mechanical energy output. The magnets in rotor assembly 5 are fixed to the rotor shaft by an interference fit and are magnetized to achieve a uniform magnetic field distribution. The design of rotor assembly 5 considers optimization of rotational inertia, improving the motor's dynamic response performance by adjusting the mass distribution and geometry of the magnets. For example, the thickness and length of the magnets are precisely calculated to ensure they do not detach due to centrifugal force during high-speed rotation. Furthermore, the surface of rotor assembly 5 undergoes a special coating treatment to enhance its corrosion resistance.

[0033] The insulating gasket 7 is located between the rotor assembly 5 and the BMC stator assembly 9 to provide electrical insulation and prevent current from flowing through non-conductive paths. The insulating gasket 7 is made of an insulating material with excellent pressure and temperature resistance, and its thickness is precisely calculated to meet the insulation requirements of the motor at rated and peak voltages. The surface of the insulating gasket 7 undergoes special treatment to enhance its moisture resistance and anti-aging properties, thereby extending the service life of the motor. For example, the surface of the insulating gasket 7 is coated with a moisture-proof coating, which effectively prevents moisture intrusion.

[0034] Power cord 8 extends from one side of the motor to connect to an external power source and provide power input to the motor. The conductor of power cord 8 employs a multi-strand stranded structure to improve flexibility and fatigue resistance, while the outer layer is covered with high-temperature resistant and wear-resistant insulating material to adapt to the motor's operating environment. The lead-out end of power cord 8 forms a sealed connection with the motor housing through an injection molding process, thereby preventing moisture and dust from entering the motor. For example, the lead-out end of power cord 8 is tightly bonded to the housing through a high-temperature injection molding process, ensuring a tight seal at the connection.

[0035] The BMC stator assembly 9, located within the motor housing and surrounding the rotor assembly 5, generates a magnetic field and drives the rotor to rotate. The BMC stator assembly 9 is integrally injection molded from BMC material, possessing excellent insulation, fire resistance, and moisture resistance. It effectively withstands internal electromagnetic forces and external installation stresses, preventing housing deformation. The windings of the BMC stator assembly 9 utilize aluminum wire technology, precisely controlling the number of turns and wire diameter to improve motor efficiency while reducing costs. For example, the windings of the BMC stator assembly 9 are wound using automated winding equipment, ensuring the uniformity and consistency of the windings.

[0036] The innovations and specific implementations of the present utility model include the following aspects. S1. High-efficiency and energy-saving design: The BMC stator assembly 9 adopts optimized winding design and magnetic field distribution, enabling the motor to reach an efficiency as high as 47%, which is significantly higher than the 25% of traditional shaded-pole motors. The winding uses aluminum wire technology, which further reduces costs compared to copper wire windings, while maintaining high performance through precise design of the number of turns and wire diameter. For example, the number of turns and wire diameter of the winding are optimized through computer simulation, ensuring the uniformity of magnetic field distribution and maximization of efficiency. S2. Low-cost manufacturing: The integral injection molding process of the BMC stator assembly 9 reduces the number of components and assembly procedures, thereby lowering production costs. The introduction of aluminum wire windings further reduces material costs, while improving space utilization by optimizing the winding layout. For example, the injection mold for the BMC stator assembly 9 is precisely designed to ensure high precision and high consistency of the components. S3. Excellent insulation, fire resistance and moisture resistance: The selection of BMC material and the injection molding process ensure the reliable operation of the stator assembly in complex working environments. The formulation of the BMC material is optimized to improve its heat resistance and flame retardant performance, so as to meet the safety requirements of the motor. For example, a flame retardant is added to the BMC material, which can maintain stable physical properties in high-temperature environments. S4. Low-noise design: The riveting installation method of the rear end cover 1 and the pressure distribution design of the wave washer 2 work together to significantly reduce the resonance noise during motor operation. The rigid structure of the BMC stator assembly 9 further reduces vibration transmission, thereby enhancing user experience. For example, the riveting points of the rear end cover 1 are optimally distributed to ensure the rigidity and stability of the connection. S5. Stable and reliable operation: The riveting installation method of the rear end cover 1 and the locking design of the split retaining ring 4 jointly ensure the stability and reliability of the motor under high-frequency vibration working conditions. The precision machining and fit clearance control of the 608 ball bearing 3 improve the operation accuracy and service life of the motor. For example, the fit clearance of the 608 ball bearing 3 is detected by precision measuring equipment to ensure high precision and long service life of the bearing. S6. Chip accumulation resistance design: The new plastic wind wheel matched with the motor reduces the possibility of lint adsorption by adjusting the angle of the blade structure. The surface of the wind wheel is specially treated to reduce the electrostatic effect, thereby further reducing the risk of lint accumulation. For example, the blade angle of the wind wheel is optimized through fluid mechanics analysis to ensure smooth air flow and low possibility of lint adsorption.

[0037] The technical effects of this invention are achieved through the above-described technical solution. The encapsulated brushless DC motor, through optimized structural design and material selection, achieves high efficiency, low cost, low noise, and excellent insulation, fire resistance, and moisture resistance, making it particularly suitable for applications under high-frequency vibration conditions, such as washer-dryer combos. The high-efficiency energy-saving design and anti-dandruff design significantly improve the user experience, while low-cost manufacturing processes meet market demands. For example, in washer-dryer combo applications, the motor of this invention can significantly shorten drying time and improve user satisfaction. Furthermore, the new plastic impeller design effectively reduces the risk of lint accumulation, thereby ensuring the normal operation of the fan and avoiding problems such as dry burning of the heating element and damage to the drying fan.

[0038] In summary, this invention, through detailed structural design and material selection, combined with practical application scenarios, provides a high-efficiency, stable, and economical solution for encapsulated brushless DC motors. This solution not only meets the current market demand for high-efficiency motors but also solves many problems associated with traditional motors through innovative design, demonstrating broad application prospects and market value.

[0039] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A plastic-encapsulated brushless DC motor, comprising: The rear end cover (1), wave washer (2), 608 ball bearing (3), open retaining ring (4), rotor component (5), insulating gasket (7), power cord (8) and BMC stator assembly (9) are characterized in that: the rear end cover (1) is rigidly connected to the motor housing by riveting; the wave washer (2) is located between the rear end cover (1) and the 608 ball bearing (3); the 608 ball bearing (3) is located at both ends of the rotor component (5); the open retaining ring (4) is fixed to the outside of the 608 ball bearing (3); the insulating gasket (7) is located between the rotor component (5) and the BMC stator assembly (9); the power cord (8) is led out from one side of the motor; and the BMC stator assembly (9) is integrally injection molded from BMC material and surrounds the rotor component (5).

2. The encapsulated brushless DC motor according to claim 1, characterized in that: The rear cover (1) is made of metal and its geometry has been optimized to reduce resonance noise.

3. The encapsulated brushless DC motor according to claim 2, characterized in that: The surface of the rear cover (1) is polished to further reduce vibration noise.

4. The encapsulated brushless DC motor according to claim 1, characterized in that: The waveform gasket (2) achieves uniform pressure distribution through waveform design, and its elastic modulus is precisely calculated to adapt to different working temperatures and load conditions.

5. The encapsulated brushless DC motor according to claim 1, characterized in that: The fit clearance between the 608 ball bearing (3) and the rotor component (5) is precision machined, and the open retaining ring (4) is made of elastic metal material and the bearing position is locked by radial elastic force.

6. The encapsulated brushless DC motor according to claim 1, characterized in that: The insulating pad (7) is made of insulating material with excellent pressure resistance and temperature resistance, and its thickness is precisely calculated to meet the insulation requirements under rated voltage and peak voltage.

7. The encapsulated brushless DC motor according to claim 1, characterized in that: The windings of the BMC stator assembly (9) use aluminum wire technology, and the number of turns and wire diameter of the windings are precisely controlled to improve motor efficiency.

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