ROTOR WITH ANTI-ANGLED SIDE SURFACE AND LAMINATIONS MADE WITH IT

Abstract

Rotor disk with a plurality of spaced teeth, each tooth having a transverse section with a first and a second end section, each having an angled side surface forming an angle that is not 90 degrees with respect to a top surface or a bottom surface of the rotor disk.

Description

INTRODUCTION

[0001] The technical field generally refers to rotors used in brushless and brushed electric motors, and specifically to rotors with an oblique angled side surface.

[0002] A rotor can comprise a stack of disks with an annular body section containing a through-hole for the shaft of an electric motor. Multiple spaced teeth can extend radially from the annular body section. Adjacent teeth of a disk are separated at one end of each tooth by a gap. In some configurations of stacked disks used in rotor construction, the gap must be enlarged to allow conductive material to be wound through each gap and into the space separating adjacent teeth. However, if disks are stacked such that adjacent disks are rotated relative to each other, sharp edges are exposed that can damage the conductive material during the winding process.

[0003] Accordingly, it is desirable to provide a rotor disk so that a plurality of such rotor disks can be stacked, with adjacent disks being rotated against each other to provide an inclined channel formed by gaps between rotor teeth, without exposing sharp corners of the rotor teeth that could damage the conductive material during the winding process. DESCRIPTION

[0004] A number of variations may comprise a product having a rotor disk with a central body section and a through-hole formed therein, and a plurality of spaced-apart teeth extending radially from the central body section, each tooth of the plurality of teeth having an elongated stem section with a first end at the central body section, and the elongated stem section extending radially to a second end terminating at a transverse section, the transverse section being generally arc-shaped and extending in a first direction from a first lateral edge of the stem section and in an opposite second direction from a second lateral edge of the stem section, a first end of the transverse section having a first side face not formed at a 90-degree angle with respect to a top or bottom face of the rotor disk.and a second end of the transverse section has a second side surface that is not formed at a 90-degree angle with respect to the top surface or the bottom surface, with transverse sections of adjacent teeth forming a gap between them.

[0005] A product may comprise a number of variations, including a plurality of rotor disks, each rotor disk having a central body section and a through-hole formed therein, and a plurality of spaced-apart teeth extending radially from the central body section, each tooth of the plurality of teeth enclosing an elongated stem section having a first end at the central body section, and the elongated stem section extending radially to a second end terminating at a transverse section, the transverse section being able to have a general arc shape and extending in a first direction from a first lateral edge of the stem section and in an opposite second direction from a second lateral edge of the stem section, a first end of the transverse section having a first side surface.which is not formed at a 90-degree angle with respect to a top or bottom face of the rotor disk, and a second end of the transverse section has a second side face which is not formed at a 90-degree angle with respect to the top or bottom face, wherein transverse sections of adjacent teeth form a gap between them, wherein the plurality of rotor disks are stacked on top of each other, wherein adjacent rotor disks are rotated with respect to each other such that the gap between transverse sections of adjacent teeth on each disk is aligned with the gap between transverse sections of adjacent teeth on an adjacent rotor disk to form an oblique channel extending over the longitudinal length of the plurality of rotor disks.

[0006] A number of variations may include a method that involves providing a rotor disk with a central body section and a through-hole formed therein, and a plurality of spaced-apart teeth extending radially from the central body section, each tooth of the plurality of teeth enclosing a longer stem section with a first end at the central body section, and the longer stem section extending radially to a second end terminating at a transverse section, the transverse section being generally arc-shaped and extending in a first direction from a first lateral edge of the stem section and in an opposite second direction from a second lateral edge of the stem section, a first end of the transverse section having a first side face formed at a 90-degree angle with respect to a top or bottom face of the rotor disk.and a second end of the transverse section has a second side face formed at a 90-degree angle with respect to the top or bottom face, with transverse sections of adjacent teeth forming a gap between them; trimming the first side face of the transverse section so that the trimmed first side face forms an angle with the top or bottom face that is not 90 degrees, and trimming the second side face of the transverse section so that the trimmed second side face forms an angle with the top or bottom face that is not 90 degrees. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The exemplary embodiments are described below in conjunction with the following drawing figures, where identical numbers denote identical elements and where:

[0008] The exemplary embodiments are described below in conjunction with the following drawings, where identical numbers denote identical elements, and where: Fig. 1A is a partial sectional view of adjacent teeth of a rotor disk; Fig. 1B is a partial sectional view of a stack of rotor disks; Fig. 2 a top view of a rotor disk according to one embodiment; Fig. 3A is a partial side view of adjacent teeth of a rotor disk according to one embodiment; Fig. 3B is a partial side view of a stack of rotor disks according to one embodiment; Fig. 4 is a partial side view of a rotor which contains a plurality of stacked rotor discs with a motor shaft included therein according to one embodiment; Fig. 5A is a partial side view of a method comprising the punching of a rotor disk according to one embodiment; Fig. 5B is a partial side view of a method comprising trimming a first tooth of two adjacent teeth of a rotor disk according to one embodiment; and Fig. Figure 5C shows a partial side view of a method involving the trimming of a second tooth from two adjacent teeth of a rotor disk according to one embodiment. DETAILED DESCRIPTION

[0009] The following detailed description is merely exemplary and is not intended to limit application and use. Furthermore, there is no intention to be bound by any express or implied theories presented in the preceding technical field, background, summary, or the following detailed description.

[0010] With reference to Fig. 1A A rotor disk 10' can be formed by punching a relatively thin, flat piece of metal with a punching tool that moves in a perpendicular direction with respect to a top surface 38' and an opposite bottom surface 40' of the thin, flat piece of metal 10'. The punching process forms a rotor disk 10', wherein a first perpendicular edge 30' extends between the top surface 38' and the opposite bottom surface 40' of the thin, flat piece of metal at a first end 26' of a transverse section 24' of a first tooth, and a second perpendicular edge 32' extends between the top surface 38' and the opposite bottom surface 40' of the thin, flat piece of metal at a second end 28' of a transverse section 24' of a second tooth immediately adjacent to the first tooth. Referring to Fig. 1B The stack of disks 10' forms an oblique channel 46' extending along the axial length of the stack of disks when several disks 10' are stacked on top of each other and adjacent disks 10' are rotated relative to each other. However, the top surface 38', the perpendicular edge 30', 32' and the bottom surface 40' at each end of the transverse section 24' form sharp corners 42', 44' which can damage conductive wire material when wound around the stack of rotor disks.

[0011] Fig. Figure 2 is a top view of a rotor disk 10 according to one embodiment. Variations of a rotor disk 10 may include a central body section 12, which may have a generally annular shape and in which a through-hole 14 may be formed to accommodate a shaft of an electric motor. A plurality of spaced-apart teeth 16 may extend radially from the central body section 14. Each tooth 16 may have a T-like shape, with each tooth 16 having an elongated stem section 18 with a first end 20 at the central body section 12. The stem section 18 may extend radially to a second end 22, which terminates in a transverse section 24. The transverse section 24 may have a general arc shape and may extend in a first direction from a first lateral edge 19 of the stem section 18 and in an opposite second direction from a second lateral edge 21 of the stem section 18.Adjacent, spaced-apart teeth 16 can form a cavity 34 for receiving conductive wiring, which is guided through the gap 36 between the transverse sections 24 of the adjacent teeth 16. The rotor disk 10 can be a single, uniform piece of stamped thin metal.

[0012] With reference to Fig. 3A A first end 26 and a second end 28 of the transverse section 24 can be clipped to create a first side face 30 and a second side face 32 that are not at a 90-degree angle with respect to the top face 38 of each transverse section 24. In several variants, the angle A formed by the top face 38 and the first side face 30 is greater than 90 degrees, and the angle B formed by the top face 38 and the second side face 32 is less than 90 degrees. In several variants, the angle A formed by the top face 38 and the first side face 30 and the angle B formed by the top face 38 and the second side face 32 are complementary or nearly complementary to each other. In several variants, the first side face or edge 30 is parallel to the second side face or edge 32.

[0013] With reference to Fig. 3B can include a number of variants of a product that contains a plurality of rotor discs 10, as in Fig. As described in Figure 3A, the rotor disks are stacked one on top of the other, each disk being rotated with respect to an adjacent disk such that an oblique channel 46 is formed by gaps 36 between the transverse sections 24 of adjacent teeth of each rotor disk 10. In a number of variations, the rotor disks are rotated such that a plurality of the first side faces 30 of a plurality of rotor disks lie in a first imaginary plane and a plurality of the second side faces 32 lie in a second imaginary plane, wherein the first imaginary plane and the second imaginary plane are parallel to each other.In several variations, the majority of stacked rotor disks 10 are stacked one on top of the other, each disk being rotated with respect to an adjacent disk such that an inclined channel 46 is formed by gaps 36 between the transverse sections 24 of adjacent teeth of each rotor disk 10, and such that no sharp corners 42, 44 are exposed at the first end 26 and second end 28, respectively, in the inclined channel 46. The channel 46 is inclined with respect to a longitudinal axis passing through the stacked rotor disk.

[0014] With reference to Fig. A rotor 72 can comprise a plurality of rotor disks 10 stacked one above the other, each disk being rotated relative to an adjacent disk such that an inclined channel 46 is formed by gaps 36 between the transverse sections 24 of adjacent teeth of each rotor disk 10, and such that no sharp corners 42, 44 at the first end 26 or second end 28 are exposed in the inclined channel 46. The plurality of disks can be laminated together with a dielectric material. An electric motor shaft 74 can be received in and attached to the plurality of disks 10. The channel 46 is inclined relative to a longitudinal axis passing through the stacked rotor disks.A vehicle may include an electric motor in which the electric motor shaft 74 is attached to the majority of the stacked rotor disks 10, each disk being rotated in relation to an adjacent disk such that an inclined channel 46 is formed by gaps 36 between the transverse sections 24 of adjacent teeth of each rotor disk 10 and such that no sharp corners 42, 44 at the first end 26 and second end 28 respectively are exposed in the inclined channel 46.

[0015] With reference to Fig. 5A, Fig. 5B and Fig. 5C can include a number of variants of a method for stamping a uniform, single piece of thin metal 8 into a rotor disk 10, which is useful in an electric motor. The stamping method can produce a rotor disk 10 as shown in the Fig. 2, Fig. 3A, Fig. 3B and Fig. 4 described. As in Fig. As shown in Figure 5A, a thin metal piece 8 can be placed on a die 48 in which a through-hole or recess 50 is formed. A bottom surface 40 of the thin metal piece 8 can rest on the die 48, and a die 52 can be moved towards the thin metal piece 8 to engage its top surface 38. The die 52 can have an elongated projection 51 with a first side surface 54 and a second side surface 56, which extend perpendicular to the top surface 38 of the thin metal piece 8. The die 52 can be advanced so that the first elongated projection 51 cuts through the thickness of the thin metal piece 8.

[0016] This can be done in a number of variations. Fig. The methods shown in 5A for manufacturing a rotor disk are used, as described in Fig. 2 is shown and described. However, the following can be understood with reference to the illustrations in the Fig. The methods described in 5A-5B are applied to a prefabricated rotor disk, as described with reference to Fig. 2 is carried out, wherein the first end 26 of a transition section 24 of a first tooth can be overlapped at a 90-degree angle from the top surface 38 of the rotor disk and an opposite second end 28 of the transition section 24 of a second, immediately adjacent tooth can be undercut at a 90-degree angle from the top surface 38 of the rotor disk.

[0017] As in Fig. As shown in 5B, the above can be compared with the Fig. A rotor disk produced by the method described in section 5A, or a rotor disk prefabricated by another method, is placed on a first tool support 64. A first punching tool 58 can be provided with a first elongated projection 57 having a first side surface 60 formed at an angle of less than 90 degrees to the top surface 58 of the thin metal piece 8. The first elongated projection 57 can have a second side surface 62 formed at an angle perpendicular to the top surface 38 of the thin metal piece 8 (rotor disk), so that the second side surface 62 of the first elongated projection 57 can be moved along a second side surface 30' of the thin metal piece 8 that was cut by the first punching tool 52.As the first punching tool 58 is moved forward through the metal piece 8, the first side face 60 clips the second end 32 of the transverse section 24 of a first tooth from adjacent teeth to provide a clipped second side face 32 of the transverse section 24. The clipped second side face 32 and the top face 38 of the transverse section 24 form an angle that is not 90 degrees.

[0018] As in Fig. As shown in Figure 5C, the thin metal piece 8 (rotor disc) with the trimmed second side surface 32 can then be placed over a second punching tool 66, which may have a second elongated projection 61 with a first side edge 68 designed and arranged to slide along the second side surface 32 of the transverse section 24 of the first tooth cut by the second punching tool 58 or to avoid contact with it. The second elongated projection 61 may have a second side surface 70 formed at an angle of less than 90 degrees with respect to the bottom surface 40 of the transverse section 24.A second embossing base 76 can be advanced towards the thin metal piece 8 (rotor disc) and press it against the second cutting tool 61, so that a trimmed first side surface 30 of the transverse section 24 of the second tooth of the adjacent teeth is cut at an angle that is not 90 degrees with respect to the top surface 38 of the transverse section 24. A plurality of rotor discs 10 can be produced using the [methods / tools / etc.]. Fig. 5A, Fig. 5B and Fig. The process steps are formed as shown in Figure 5C. The process can further include stacking the plurality of disks and rotating each adjacent disk such that the gap 36 between the transverse sections 24 of adjacent teeth forms an inclined channel 46 extending over the axial length of the stack of the plurality of rotor disks 10, as shown in Figure 5C. Fig.Figure 4 shows that the majority of the rotor disks 10 can be stacked together and an electric motor shaft 74 can be received in the through hole 14 formed in each rotor disk.

[0019] Although at least one exemplary embodiment has been presented in the preceding detailed description, it should be understood that there are numerous variations. It should also be noted that the exemplary embodiment or embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of the disclosure in any way. Rather, the preceding detailed description is intended to provide the person skilled in the art with a practical guide for implementing the exemplary embodiment or embodiments. It is understood that various modifications to the function and arrangement of the elements can be made without departing from the scope of the disclosure as set forth in the appended claims and their statutory equivalents.

[0020] Although at least one exemplary embodiment has been presented in the preceding detailed description, it should be understood that a large number of variations exist. It should also be recognized that the embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of the disclosure in any way. Rather, the preceding detailed description is intended to provide the person skilled in the art with practical guidance for implementing the embodiments. It is understood that various modifications to the function and arrangement of the elements can be made without departing from the scope of the disclosure as set forth in the appended claims and their statutory equivalents.

Claims

[1] A product comprising: a rotor disk having a central body portion and having a through-hole formed therein and a plurality of spaced-apart teeth extending radially from the central body portion, each tooth of the plurality of teeth having an elongated root portion with a first end at the central body portion, and wherein the elongated root portion extends radially to a second end terminating at a transverse portion, the transverse portion having a generally arcuate shape and extending in a first direction from a first side edge of the root portion and in an opposite second direction from a second side edge of the root portion, a first end of the transverse portion having a first side surface that is not formed at a 90-degree angle with respect to a top surface or a bottom surface of the rotor disk, and a second end of the transverse portion having a second side surface,which is not formed at a 90-degree angle with respect to the top surface or the bottom surface, with transverse sections of adjacent teeth forming a gap therebetween. [2] The product according to claim 1, wherein an angle A formed by the top surface and the first side surface of the transverse section is greater than 90 degrees and an angle B formed by the top surface and the second side surface of the transverse section is less than 90 degrees. [3] The product according to claim 1, wherein an angle A formed by the top surface and the first side surface and an angle B formed by the top surface and the second side surface complement or nearly complement each other. [4] The product of claim 1, wherein the central body portion has a generally circular ring shape. [5] The product of claim 1, wherein the rotor disc is a unitary, single piece of stamped thin metal. [6] A procedure comprising:Providing a rotor disk having a central body portion and a through-hole formed therein and a plurality of spaced-apart teeth extending radially from the central body portion, each tooth of the plurality of teeth comprising an elongated root portion having a first end at the central body portion, and wherein the elongated root portion extends radially to a second end terminating at a transverse portion, the transverse portion having a generally arcuate shape and extending in a first direction from a first side edge of the root portion and in an opposite second direction from a second side edge of the root portion, a first end of the transverse portion having a first side surface formed at a 90-degree angle with respect to a top surface or a bottom surface of the rotor disk, and a second end of the transverse portion having a second side surface,which is formed at a 90-degree angle with respect to the top surface or the bottom surface, with transverse sections of adjacent teeth forming a gap therebetween;, Trimming the first side surface of the transverse section such that a trimmed first side surface forms an angle with the top surface or bottom surface that is not 90 degrees; and trimming the second side surface of the transverse section such that the trimmed second side surface forms an angle with the top surface or bottom surface that is not 90 degrees. [7] The method of claim 6, wherein an angle A formed by the top surface and the trimmed first side surface of the transverse section is greater than 90 degrees and an angle B formed by the top surface and the trimmed second side surface 32 of the transverse section is less than 90 degrees. [8] The method according to claim 6, wherein an angle A formed by the top surface and the trimmed first side surface and an angle B formed by the top surface and the trimmed second side surface complement or nearly complement each other. [9] The method of claim 6, wherein trimming the second side surface of the transverse section comprises then placing the rotor disk on a first punch base, moving a punch having a first elongated projection having a first side surface formed at an angle that is not 90 degrees with respect to the top surface of the rotor disk, the first elongated projection having a second side surface formed at an angle perpendicular to the top surface of the rotor disk, and such that the second side surface of the first elongated projection is movable along the second side surface of the transverse section of the rotor disk such that the first side surface of the elongated projection trims an end of the transverse section of a first of adjacent teeth to provide a trimmed second side surface of the transverse section. [10] The method of claim 9, wherein trimming the first side surface of the transverse portion comprises placing the rotor disc over a second punching tool having a second elongated projection with a first side edge constructed and arranged to slide along or avoid contact with the trimmed second side surface of the transverse portion of the first tooth trimmed by the first punching tool, the second elongated projection having a second side surface formed at an angle other than 90 degrees with respect to the bottom surface of the transverse portion, a second punching base being advanced towards the rotor disc pressing it against the second punching tool such that a first side surface of the transverse portion of the second tooth of the adjacent teeth is cut at an angle other than 90 degrees with respect to the top surface of the transverse portion.

Images