Brush assembly, conductive device, and internal rotor motor

Abstract

The present invention relates to a brush assembly, a conductive device, and an internal rotor motor, wherein the brush assembly includes a support and at least two brush elements spaced apart in the axial direction. Each brush element includes an elastic element and a carbon brush. Each elastic element includes a fixed end fixedly coupled to the support and a free end opposite the fixed end. Each carbon brush is fixed to the free end of the corresponding elastic element and includes a contact surface for sliding contact with a slip ring. The outward direction of the carbon brush or the outward-facing contact surface avoids the support and all elastic elements. By pushing the carbon brush with the free end of the elastic element, the slip ring can continue to move along the intended assembly direction until it reaches a predetermined position relative to the support. The brush assembly of the present invention does not form a closed internal region, thus eliminating the need for a special tool to push each elastic element outward, thereby simplifying the assembly of the internal rotor motor and improving the assembly efficiency of the internal rotor motor.

Description

Technical Field

[0001] This application relates to the field of motor technology, and more particularly, to brush assemblies, conductive devices, and internal rotor motors.

Background Art

[0002] Motors generally include a stator and a rotor, and the rotor is rotatable relative to the stator. Based on the internal and external positional relationships between the stator and the rotor, motors can be classified into two main types: internal rotor motors and external rotor motors. In an internal rotor motor, the stator surrounds the rotor, and the rotor rotates within the stator.

[0003] During the rotation of the rotor, usually, the brushes need to cooperate with the commutator or slip rings to achieve electrical conduction of the rotor. When the slip rings on the rotor need to contact a plurality of brushes, in the prior art, generally, in order to ensure insulation between each brush, the brushes are evenly displaced along the outer peripheral direction of the rotor for arrangement. However, during the assembly of the motor, when the brushes are incorporated, each brush tends to move towards the central axis under the action of the spring. As a result, the diameter of the internal region surrounded by the brushes in its natural state is smaller than the diameter of the slip rings. During motor assembly, the slip rings cannot be directly inserted axially into the internal region defined by the plurality of brushes. Instead, a jig for pushing each brush outward is required, whereby the diameter of the internal region defined by the brushes needs to be enlarged before the slip rings are inserted axially. The need to use special tools to push the brushes during motor assembly makes the motor assembly procedure relatively complicated, which does not contribute to improving the assembly efficiency of the motor.

Summary of the Invention

Means for Solving the Problems

[0004] Accordingly, the present invention provides a brush assembly, a conductive device, and an internal rotor motor that can solve or at least mitigate the technical problems described above.

[0005] The present invention provides a brush assembly, and the brush assembly is Support and At least two brush elements are spaced apart along the axis, Includes, Each brush element includes an elastic element and a carbon brush. Each elastic element includes a fixed end that is permanently connected to the support and a free end on the opposite side of the fixed end. Each carbon brush is fixed to the free end of the corresponding elastic element and includes a contact surface for sliding contact with the slip ring. The outward direction of the contact surface facing outward from the carbon brush avoids the support and all elastic elements.

[0006] In the brush assembly described above, the fixed end of the elastic element is coupled to the support, so the fixed end of the elastic element is in a stable position. The elastic element can be elastically deformed within a certain range, and the carbon brush fixed to the free end can change position relative to the fixed end. The central axis of the slip ring is parallel or nearly parallel to the axial direction. When the slip ring moves radially toward the brush assembly, the intended mounting direction of the slip ring is perpendicular or nearly perpendicular to the axial direction. If the intended mounting direction of the slip ring is parallel or nearly parallel to the outward direction of the contact surface, the outward direction avoids the support and all elastic elements when the elastic element is in a free state, so as the slip ring approaches the contact surface of the carbon brush along the intended mounting direction, the slip ring is not obstructed by the support or elastic elements. After the slip ring has just made contact with the contact surface of the carbon brush, the slip ring can continue to move along the intended mounting direction by pushing the carbon brush with the free end of the elastic element until the slip ring reaches a predetermined position relative to the support. At this time, the elastic elements deform somewhat under the pressure of the slip ring, ensuring that the carbon brushes are stably mounted on the surface of the slip ring. Since at least two brush elements are spaced apart axially and the outward direction of the contact surfaces avoids the support and all elastic elements, when the slip ring is assembled, it can be used directly to reach a position that contacts all contact surfaces of the carbon brushes and coincides with a predetermined position. Since the brush assembly of this application does not form a closed internal region, the slip ring can be assembled directly by pressing it onto the carbon brushes from the radial direction, eliminating the need for a special tool to push each elastic element outward, thereby simplifying the assembly of the internal rotor motor and improving the assembly efficiency of the internal rotor motor.

[0007] In one embodiment, on a plane perpendicular to the axial direction, a first central angle corresponding to the projection of all free ends is not greater than a second central angle corresponding to the projection of all fixed ends, the first central angle is the central angle of the span of projections of all free ends in the circumferential direction around the axis, the second central angle is the central angle of the span of projections of all fixed ends in the circumferential direction around the axis, and the axis is the projection of the central axis of the slip ring on a plane perpendicular to the axial direction when the carbon brush is combined with the slip ring.

[0008] In one embodiment, two axially adjacent carbon brushes are arranged in a staggered pattern along the axial direction.

[0009] In one embodiment, on a plane perpendicular to the axial direction, the central angle of the projections of two axially adjacent carbon brushes around the axis is equal to the central angle of the span of the projections of all carbon brushes in the circumferential direction around the axis.

[0010] In one embodiment, the support includes a mounting portion and a support portion, one end of the support portion is connected to the mounting portion, and the other end is connected to the fixed end of the elastic element, and the distance between the free end and the mounting portion is less than the distance between the fixed end and the mounting portion.

[0011] In one embodiment, the side surface of the mounting portion is provided with a first guide groove, which is configured for axial guidance and radial restriction when the brush assembly is mounted in a first recess of the stator housing.

[0012] In one embodiment, the mounting portion includes a second guide groove, which is configured for radial guidance and axial restriction when the brush assembly is coupled to a second recess in the end cover.

[0013] In one embodiment, the mounting portion includes at least two axially adjacent seat portions, each seat portion engaging with an adjacent seat portion, and the support portion includes at least two conductive sheets, one end of each conductive sheet passing through one of the seat portions and the other end coupled to a fixed end of an elastic element.

[0014] In one embodiment, each seat portion is provided with a positioning groove, and each conductive sheet is at least partially inserted into the positioning groove of the corresponding seat portion.

[0015] The present invention provides a conductive device comprising a slip ring and a brush assembly, the slip ring comprising at least two conductive rings insulated from each other, and the contact surface of each carbon brush abuts against one of the conductive rings.

[0016] The present invention provides an internal rotor motor comprising a stator assembly and a rotor assembly rotatably disposed within the stator assembly, wherein the stator assembly comprises a stator housing, magnets disposed on the inner wall of the stator housing, and a brush assembly, the magnets forming a steady magnetic field relative to the stator housing; the rotor assembly comprises a core, a rotating shaft inserted into the core, and coils wound around the core, the rotating shaft being sleeved with slip rings electrically connected to the coils, and the contact surfaces of the brush assembly abutting against the slip rings. [Brief explanation of the drawing]

[0017] [Figure 1] This is a schematic perspective view of an internal rotor motor according to one embodiment of the present application. [Figure 2] Figure 1 is a schematic perspective view of the internal rotor motor, seen from a different angle. [Figure 3] Figure 2 is a schematic diagram of the internal rotor motor after disassembly. [Figure 4] Figure 2 is a schematic diagram of the internal rotor motor viewed from a different angle. [Figure 5] Figure 4 is a schematic perspective view of the brush assembly of the internal rotor motor, where the brush assembly is in a free state. [Figure 6] It is a schematic perspective view of the brush assembly of the internal rotor motor shown in FIG. 4 from another angle. [Figure 7] It is a schematic exploded view of the brush assembly shown in FIG. 6. [Figure 8] It is a schematic exploded view of the brush assembly shown in FIG. 6 from another angle. [Figure 9] It is a schematic partial exploded view of the brush assembly shown in FIG. 6. [Figure 10a] It is a top view of the brush assembly shown in FIG. 5. [Figure 10b] It is a top view of the brush assembly shown in FIG. 5, and the slip ring is in contact with the carbon brush. [Figure 11a] It is a schematic perspective view of the brush assembly in a free state according to an embodiment of the present application. [Figure 11b] It is a top view of the brush assembly shown in FIG. 11a. [Figure 12] It is a side view of the internal rotor motor according to another embodiment of the present application. [Figure 13] It is a schematic view of the assembled internal rotor motor according to yet another embodiment of the present application. [Figure 14] It is a top view of the brush assembly of the internal rotor motor shown in FIG. 13, and the elastic element is in a state of being pushed by the slip ring.

Embodiments for Carrying Out the Invention

[0018] Hereinafter, together with the accompanying drawings, the technical solution of the present application will be clearly and completely described. It is clear that the described embodiments are part of the embodiments of the present application, not all of the embodiments. Based on the embodiments of the present application, all other embodiments that can be obtained by those skilled in the art without creative activities are within the protection scope of the present application.

[0019] In the description of this application, terms such as “center,” “top,” “bottom,” “left,” “right,” “vertical,” “horizontal,” “inside,” and “outside” should be noted as indicating orientations or positional relationships based on the orientations or positional relationships shown in the drawings. These terms are merely for convenience to describe and simplify the description of this application and do not indicate or suggest that the described devices or components must have a particular orientation or must be configured and operate in a particular orientation; therefore, these terms should not be construed as limitations of this application. In addition, terms such as “first,” “second,” and “third” are used for illustrative purposes only and do not indicate or suggest relative importance.

[0020] In the description of this application, unless otherwise specified, the terms “integrate,” “connect,” and “join” should be understood in a broad sense. For example, these may refer to fixed bonds, detachable bonds, integral bonds, mechanical bonds, electrical bonds, direct bonds, bonds via an intermediate medium, or mutual bonds between two elements. Those skilled in the art will be able to understand the specific meanings of these terms in this application based on the particular context.

[0021] The technical solutions provided by the embodiments of this application will be described below, in conjunction with the attached drawings.

[0022] As shown in Figures 1 to 14, this application provides an internal rotor motor 100. The internal rotor motor 100 can be used as a drive component that outputs drive torque in the automotive field or other industrial fields (home appliances, power tools, etc.).

[0023] In some embodiments, as shown in Figures 3 and 4, the internal rotor motor 100 includes a stator assembly and a rotor assembly 30 rotatably disposed within the stator assembly.

[0024] In some embodiments, as shown in Figure 3, the stator assembly includes a stator housing 20, magnets 50 positioned on the inner wall of the stator housing 20, and a brush assembly 70. The magnets 50 generate a steady magnetic field relative to the stator housing 20. The rotor assembly 30 includes a core 32, a rotating shaft 31 inserted into the core 32, and coils 33 wound around the core 32. The rotating shaft 31 is sleeved with slip rings 90 electrically connected to the coils 33. Specifically, the magnets 50 can be magnetic components or other magnetic components.

[0025] In some embodiments, the coil 33 can be a multiphase coil or a single-phase coil, and correspondingly, the external power supply can be an AC (alternating current) power supply such as a multiphase or single-phase AC power supply. When the coil 33 is a multiphase coil, the number of conductive rings 91 is at least the number of phases of the multiphase coil, and each phase coil 33 is electrically connected to one of the conductive rings 91, and each phase coil 33 can be connected to the external power supply via one conductive ring 91. Preferably, the number of conductive rings 91 is equal to the number of phases of the multiphase coil. When the coil 33 is a single-phase coil, the number of conductive rings 91 is two, and the two conductive rings 91 connect the leading and trailing ends of the single-phase coil, respectively, and both ends of the single-phase coil can be connected to the external power supply via one conductive ring 91.

[0026] In some embodiments, as shown in Figure 3, the magnets 50 are arranged at regular intervals in the circumferential direction of the stator housing 20, and adjacent magnets 50 have opposite polarities. That is, if one of two adjacent magnets 50 has a radially inner end of the north pole and a radially outer end of the south pole, the other will have a radially inner end of the south pole and a radially outer end of the north pole. Thus, alternating north and south poles are formed in the circumferential direction inside the stator housing 20, creating a steady stator magnetic field for the stator housing 20. In some embodiments, the magnets 50 are made from a weakly magnetic material such as ferrite. The magnets 50 can also be made from a ferromagnetic material such as neodymium-iron-boron. Furthermore, the magnets 50 can also be electromagnets.

[0027] In some embodiments, as shown in Figure 3, the stator housing 20 includes a first recess 21. In some embodiments, the first recess 21 is located on the edge of the open end 22 of the stator housing 20. In some embodiments, the core 32 can be made from laminated silicon steel sheets, including a yoke portion that is sleeved onto a rotating shaft 31, and a plurality of toothed portions that extend radially outward from the yoke portion. The rotating shaft 31 is fixedly inserted into the yoke portion of the core 32, and both ends of the rotating shaft 31 extend outward from the core 32 to transmit power to the outside. The coil 33 is wound around each toothed portion, and adjacent toothed portions are spaced apart in the circumferential direction to form a winding groove for the coil 33.

[0028] In some embodiments, as shown in Figures 3 and 4, the internal rotor motor 100 also includes an end cover 80. The end cover 80 is configured to cover the open end 22 of the stator housing 20. In some embodiments, the end cover 80 is located inside the open end 22 of the stator housing 20. In some embodiments, the internal rotor motor 100 also includes a bearing component 81. The bearing component 81 may be located between the stator housing 20 and the rotating shaft 31. The bearing component 81 may also be located between the end cover 80 and the rotating shaft 31. In some embodiments, as shown in Figure 13, the end cover 80 includes a second recess 82. In some embodiments, the second recess 82 extends radially from the outer edge of the end cover 80 toward the center of the end cover 80.

[0029] As shown in Figures 3 and 4, the present application includes a conductive device 40. The conductive device 40 is configured to conduct electric current to a coil 33. When electric current flows through the coil 33, the coil 33 rotates relative to the stator housing 20 by the action of an electromagnetic force. In some embodiments, the conductive device 40 includes a slip ring 90 and a brush assembly 70. The slip ring 90 is fixedly sleeved to the rotating shaft 31 and rotates with the rotating shaft 31. The slip ring 90 is electrically connected to the coil 33. The brush assembly 70 is fixed relative to the stator housing 20. The brush assembly 70 and the slip ring 90 maintain an electrical connection by sliding contact.

[0030] In some embodiments, as shown in Figure 3, the slip ring 90 includes at least two conductive rings 91 that are insulated from each other. The at least two conductive rings 91 are arranged in a continuous, spaced-apart manner along the axial direction F1. In some embodiments, the diameters of the at least two conductive rings 91 may be the same or different.

[0031] As shown in Figures 5 and 6, the application also provides a brush assembly 70 applicable to at least the conductive device 40 or the internal rotor motor 100 described above. In some embodiments, the brush assembly 70 includes a support 71 and at least two brush elements 74 spaced apart along an axial direction F1. Each brush element 74 includes an elastic element 75 and a carbon brush 76. Each elastic element 75 includes a fixed end 751 fixedly coupled to the support 71 and a free end 752 opposite the fixed end 751. Each carbon brush 76 is fixed to the free end 752 of the corresponding elastic element 75 and has a contact surface 761 for sliding contact with the slip ring 90. The outward direction F3 of the contact surface 761, as viewed from the carbon brush 76, avoids the support 71 and all the elastic elements 75.

[0032] Specifically, since the fixed end 751 of the elastic element 75 is coupled to the support 71, the fixed end 751 of the elastic element 75 is in a stable position. The elastic element 75 can elastically deform within a certain range, allowing the carbon brush 76, fixed to the free end 752, to change position relative to the fixed end 751. The central axis of the slip ring 90 is parallel or nearly parallel to the axial direction F1. When the slip ring 90 moves radially toward the brush assembly 70, the intended mounting direction F2 of the slip ring 90 is perpendicular or nearly perpendicular to the axial direction F1. If the intended mounting direction F2 of the slip ring 90 is parallel or nearly parallel to the outward direction F3 of the contact surface 761, the outward direction F3 avoids the support 71 and all the elastic elements 75 when the elastic element 75 is in a free state, so the slip ring 90 is not obstructed by the support 71 or the elastic elements 75 as it approaches the contact surface 761 of the carbon brush 76 along the intended mounting direction F2. After the slip ring 90 has just made contact with the contact surface 761 of the carbon brush 76, the slip ring 90 can continue to move along the intended mounting direction F2 by pushing the carbon brush 76 with the free end 752 of the elastic element 75 until the slip ring 90 reaches a predetermined position relative to the support 71. At this point, the elastic element 75 deforms somewhat under the pressure of the slip ring 90, which ensures that the carbon brush 76 is stably mounted on the surface of the slip ring 90. Since at least two brush elements 74 are spaced apart in the axial direction F1 and the outward direction F3 of the contact surface 761 avoids the support 71 and all the elastic elements 75, when mounting the slip ring 90, it can be used directly to reach a position where it abuts against all the contact surfaces 761 of the carbon brush 76 and aligns with the predetermined position. Since the brush assembly 70 of this application does not form a closed internal region, the slip ring 90 can be directly assembled by pressing it against the carbon brush 76 from the radial direction, eliminating the need for a special tool to push each elastic element 75 outward, thereby simplifying the assembly of the internal rotor motor 100 and improving the assembly efficiency of the internal rotor motor 100.

[0033] Specifically, as shown in Figures 5 and 10a, the front side of the elastic element 75 faces outward when viewed from the support 71, and the back side of the elastic element 75 faces the support 71. The carbon brush 76 is positioned in front of the elastic element 75. It can be understood that the outward direction F3 of the contact surface 761 avoids the front of the elastic element 75 and avoids the extended space in front of the elastic element 75 along the axial direction F1, for the reason that the outward direction F3 of the contact surface 761 avoids the elastic element 75. In some embodiments, the outward direction F3 of the contact surface 761 may be directed towards the extended space on the back of the elastic element 75 along the axial direction F1.

[0034] In some embodiments, as shown in Figures 5 and 10a, the support 71 includes a mounting portion 72 and a support portion. One end of the support portion is coupled to the mounting portion 72, and the other end is coupled to the fixed end 751 of the elastic element 75. The distance between the free end 752 and the mounting portion 72 is smaller than the distance between the fixed end 751 and the mounting portion 72. Specifically, the support 71 is attached to other devices via the mounting portion 72. The support portion allows support for the fixed end 751 of the elastic element 75 and ensures that the fixed end 751 is in a stable position. Specifically, in the free state, the distance between the free end 752 and the mounting portion 72 is smaller than the distance between the fixed end 751 and the mounting portion 72. The free end 752 of the elastic element 75 and the mounting portion 72 are arranged relatively spaced apart in a predetermined assembly direction F2 of the slip ring 90. When the slip ring 90 pushes the carbon brush 76 along a predetermined mounting direction F2, the elastic element 75 deforms more clearly elastically, and the carbon brush 76 receives more sufficient elastic force, thus maintaining stable sliding contact with the slip ring 90. In some embodiments, the mounting portion 72 is insulated to prevent short-circuit contact between the conductive sheet 73 and other components.

[0035] In some embodiments, as shown in Figures 3 and 6, the support 71 is attached to the stator housing 20 via mounting portions 72. In other embodiments, the support 71 is attached to the end cover 80 via mounting portions 72. In some embodiments, the mounting portions 72 of the support 71 engage with a first recess 21, and after the support 71 is at least partially housed inside the stator housing 20, the brush assembly 70 can be in a relatively stable position.

[0036] In some embodiments, as shown in Figures 3 and 6, the side surface of the mounting portion 72 includes a first guide groove 728 that provides axial guidance F1 and radial restriction when the brush assembly 70 is mounted to the first recess 21 of the stator housing 20. Specifically, the first guide groove 728 is located on the outer surface of the mounting portion 72. When the brush assembly 70 is assembled into the stator housing 20, the edge of the stator housing 20 defining the first recess 21 is inserted into the first guide groove 728 in an axial direction F1. The edge of the first recess 21 provides axial guidance F1 for the mounting portion 72. In addition, the width of the first guide groove 728 corresponds to the thickness of the stator housing 20, thereby restricting the radial relative position between the mounting portion 72 and the stator housing 20. In some embodiments, the two edges of the stator housing 20 defining the first recess 21 can form an interference fit with the inner wall surface of the first guide groove 728.

[0037] In some embodiments, as shown in Figure 6, the mounting portion 72 includes an inner seat portion 721, an outer seat portion 722, and a transition portion 723. The inner seat portion 721 is configured to be located inside the stator housing 20. The outer seat portion 722 is located outside the stator housing 20. The transition portion 723 is coupled between the inner seat portion 721 and the outer seat portion 722. The width of the inner seat portion 721 along the circumferential direction of the stator housing 20 is greater than the width of the first recess 21 along the circumferential direction of the stator housing 20. The width of the outer seat portion 722 along the circumferential direction of the stator housing 20 is greater than the width of the first recess 21 along the circumferential direction of the stator housing 20. The width of the transition portion 723 along the circumferential direction of the stator housing 20 is less than or equal to the width of the first recess 21 along the circumferential direction of the stator housing 20. A first guide groove 728 is formed radially between the inner seat portion 721 and the outer seat portion 722. When the transition portion 723 is housed in the first recess 21, the inner seat portion 721 is housed inside the stator housing 20, and the outer seat portion 722 is positioned outside the stator housing 20. In some embodiments, a portion of the surface of the inner seat portion 721 is positioned facing the inner wall of the stator housing 20 and includes a convex rib 720. The convex rib 720 is configured to abut against the inner wall of the stator housing 20, increasing friction between the inner seat portion 721 and the inner wall of the stator housing 20, and consequently increasing the mounting stability between the mounting portion 72 and the stator housing 20.

[0038] In some embodiments, as shown in Figure 13, the mounting portion 72 includes a second guide groove 729 that provides radial guidance and axial restriction F1 when the brush assembly 70 is fitted into the second recess 82 of the end cover 80. Specifically, one side of the mounting portion 72 faces outward when viewed from inside the stator housing 20, and the second guide groove 729 is formed on this side of the mounting portion 72. When the brush assembly 70 is fitted and assembled into the end cover 80, the edge of the end cover 80 near the second recess 82 is inserted radially into the second guide groove 729. The second guide groove 729 restricts the relative movement direction of the edge of the end cover 80 near the second recess 82. In addition, the width of the second guide groove 729 corresponds to the thickness of the end cover 80, and as a result restricts the relative position of the mounting portion 72 and the end cover 80 in axial F1.

[0039] In some embodiments, as shown in Figure 12, the internal rotor motor 100 also includes a side wall element 23. The support 71 is attached to the side wall element 23 via a mounting portion 72. The side wall element 23 works in cooperation with the support 71 to form a structure that can surround the brush element 74. The side wall element 23 and the support 71 are coupled to the open end 22 of the stator housing 20. After the slip ring 90 pushes and deforms the free end 752 of the elastic element 75, the side wall element 23 moves toward the support 71 from the side of the slip ring 90 facing outward as viewed from the support 71, and coupled with the support 71 to form a structure that surrounds the slip ring 90. In some embodiments, the edges of the side wall element 23 are arc-shaped. The side wall element 23 and the support 71 have a circumferentially complementary relationship with respect to angles, and as a result, form a structure that surrounds the slip ring 90 in the circumferential direction. In some embodiments, the support 71 and the side wall element 23 are confined between the end cover 80 and the open end 22 of the stator housing 20. In some embodiments, the end cover 80 can be fixedly coupled to the stator housing 20, in which case the end cover 80 and the open end 22 of the stator housing 20 can clamp and secure the side wall element 23 and the support 71 from both sides, respectively.

[0040] In some embodiments, as shown in Figures 6 to 9, the mounting portion 72 includes at least two seat portions 724 arranged adjacent to each other along the axial direction F1. Each seat portion 724 engages with an adjacent seat portion 724. The support portion includes at least two conductive sheets 73, one end of each conductive sheet 73 passing through a seat portion 724 and the other end coupled to a fixed end 751 of an elastic element 75. Specifically, the fixed end 751 of the elastic element 75 is coupled to the conductive sheet 73. The engagement between the seat portions 724 ensures that the different conductive sheets 73 maintain a stable positional relationship. If a defect is found in any part of a seat portion 724 or conductive sheet 73, the defective seat portion 724 or conductive sheet 73 can be easily replaced from the support 71 by disengaging the engagement between the seat portions 724, thereby avoiding the need to discard the entire brush assembly 70. Since both the conductive sheet 73 and the elastic element 75 are conductive, after the position of the conductive sheet 73 is restricted by the mounting portion 72, the conductive sheet 73 can not only support the elastic element 75 but also establish conductivity between the elastic element 75 and the external power supply. This helps to simplify the structure of the brush assembly 70. In some embodiments, both ends of the conductive sheet 73 are exposed to the outside of the mounting portion 72.

[0041] In some embodiments, as shown in Figures 7 and 8, one of two seat portions 724, which are adjacent to each other along the axial direction F1, is coupled to an engagement block 726, which protrudes relatively from the coupled seat portion 724 toward the other seat portion 724. The other seat portion 724 is provided with an engagement slot 727. The engagement block 726 is configured to be positioned within the engagement slot 727, so that each seat portion 724 can engage with an adjacent seat portion 724. In some embodiments, the engagement block 726 forms an interference fit with the inner wall of the engagement slot 727, thereby increasing the bonding strength between the two adjacent seat portions 724 and making the structure of the mounting portion 72 more stable.

[0042] In some embodiments, as shown in Figure 7, the engagement block 726 and engagement slot 727 are located on the inner seat portion 721 of the mounting portion 72, i.e., they are located on the side surface of the mounting portion 72 facing the slip ring 90. In some embodiments, as shown in Figure 8, the engagement block 726 and engagement slot 727 are located on the outer seat portion 722 of the mounting portion 72, i.e., they are located on the side surface of the mounting portion 72 facing outward from the slip ring 90. In some embodiments, the upper seat portion 724 along the axial direction F1 comprises an engagement block 726, which protrudes toward the lower seat portion 724 along the axial direction F1. The lower seat portion 724 comprises an engagement groove 727, which opens toward the upper seat portion 724 and accommodates the engagement block 726 of the upper seat portion 724. Because the distributed arrangement of the engagement blocks 726 and engagement slots 727 is directional, if the orientation of the seat portions 724 is incorrectly reversed, the engagement blocks 726 of one seat portion 724 will come into contact with the engagement blocks 726 of the other seat portion 724. Therefore, it is not possible to assemble two seat portions 724 together in the wrong orientation, which helps to ensure the staggered arrangement of adjacent conductive sheets 73 or brush elements 74.

[0043] In some embodiments, as shown in Figures 7 and 9, each seat portion 724 is provided with a positioning groove 725, and each conductive sheet 73 is inserted into the positioning groove 725 of at least partially corresponding seat portions 724. This ensures a stable positional relationship between the conductive sheet 73 and the corresponding seat portion 724. In some embodiments, an interference fit is formed between the conductive sheet 73 and the inner wall surface of the positioning groove 725. In some embodiments, the opening of the positioning groove 725 of one seat portion 724 faces another seat portion 724. Specifically, when the seat portion 724 is disassembled, the opening of the positioning groove 725 is exposed, and the conductive sheet 73 can be removed from the seat portion 724.

[0044] In some embodiments, with respect to two adjacent seat portions 724 along the axial direction F1, a portion of the conductive sheet 73 is inserted into the positioning groove 725 of one seat portion 724 and another portion is inserted into the positioning groove 725 of the other seat portion 724. Since the conductive sheet 73 is inserted into the adjacent seat portions 724 simultaneously, it can provide a positioning function for the two adjacent seat portions 724, allowing for more precise engagement between the two adjacent seat portions 724. When the conductive sheet 73 forms an interference fit with the inner wall of the positioning groove 725, the friction between the conductive sheet 73 and the seat portion 724 can increase the bonding strength between the two adjacent seat portions 724, and as a result, a more stable relative positional relationship can be maintained between the two adjacent seat portions 724.

[0045] In some embodiments, as shown in Figures 10a and 10b, the bent end of the conductive sheet 73 is welded to one end of the elastic element 75.

[0046] In some embodiments, as shown in Figures 7 and 9, the conductive sheet 73 includes an outward-extended section 731, a transverse-extended section 732, and a longitudinal-extended section 733. The transverse-extended section 732 is coupled between the outward-extended section 731 and the longitudinal-extended section 733. The outward-extended section 731 and the longitudinal-extended section 733 are bent in different directions relative to the transverse-extended section 732. The fixed end 751 of the elastic element 75 is coupled to the longitudinal-extended section 733. Due to the bending of the transverse-extended section 732 relative to the outward-extended section 731, when the outward-extended sections 731 of the conductive sheet 73 are essentially parallel to each other, the longitudinal-extended sections 733 of adjacent conductive sheets 73 can be arranged in a staggered pattern along the axial direction F1 by extending the transverse-extended sections 732 of adjacent conductive sheets 73 in opposite directions relative to the outward-extended sections 731. This creates a larger insulating space between the two opposing longitudinally extended sections 733 along the axial direction F1. As a result, when the longitudinally extended sections 733 are exposed to the outside of the mounting portion 72, an insulating effect between adjacent conductive sheets 73 is ensured.

[0047] In some embodiments, as shown in Figures 7 and 9, the extension direction of the lateral extension section 732 relative to the lateral extension section 731 is parallel or substantially parallel to the relative direction F4 between the two fixed ends 751. The extension direction of the longitudinal extension section 733 relative to the lateral extension section 732 is substantially parallel to the intended mounting direction F2. In some embodiments, as shown in Figures 13 and 14, the end 735 of the longitudinal extension section 733 that is separated from the lateral extension section 732 is bent and positioned. The fixed end 751 of the elastic element 75 is coupled to the end 735 of the longitudinal extension section 733 and has a corresponding bent structure. This increases the contact area between the end 735 of the lateral extension section 732 and the fixed end 751 of the elastic element 75 in a limited space, ensuring conductivity stability.

[0048] In some embodiments, as shown in Figures 7 and 9, the conductive sheet 73 further includes pin sections 734 coupled to an outward extension section 731. The pin sections 734 are exposed outside the mounting portion 72 and are configured to be connected to an external power supply. In some embodiments, with respect to two adjacent conductive sheets 73 along the axial direction F1, the pin sections 734 of the two conductive sheets 73 are arranged in a staggered pattern, thereby increasing the relative distance between the two pin sections 734 and improving insulation.

[0049] In some embodiments, as shown in Figures 7 and 9, the extension direction of the outer extension section 731 is parallel to the radial direction of the stator housing 20. As a result, the outer extension section 731 can extend between the inside and outside of the stator housing 20 for a relatively short length.

[0050] In some embodiments, as shown in Figure 14, when the carbon brushes 76 and slip rings 90 are assembled, the projection of the central axis of the slip rings 90 on a plane perpendicular to the axial direction F1 functions as the axis. The central angles of the circumferential spans around the axis of the projections of all free ends 752 form a first central angle β1, and the central angles of the circumferential spans around the axis of the projections of all fixed ends 751 form a second central angle β2. Specifically, when the internal rotor motor 100 is operated, the rotor assembly 30 rotates around the axis.

[0051] In some embodiments, as shown in Figure 14, the first central angle β1 corresponding to the projection of all free ends 752 on a plane perpendicular to the axial direction F1 is not greater than the second central angle β2 corresponding to the projection of all fixed ends 751. Thus, all free ends 752 are within the circumferential distribution range of all fixed ends 751. Because the carbon brushes 76 are coupled to the free ends 752, it is ensured that each carbon brush 76 can contact the slip ring 90 as the slip ring 90 moves toward the carbon brushes 76 along the intended assembly direction F2, even if the outer diameter of the slip ring 90 is relatively small. This reduces the limitations on the outer diameter size of the carbon brushes 76. In some embodiments, both the first central angle β1 and the second central angle β2 are central angles close to the mounting portion 72. Thus, the mounting portion 72, the support portion, and the brush assembly 70 are all located on the same side of the slip ring 90, facilitating the assembly process.

[0052] In some embodiments, the elastic element 75 is formed by processing a conductive metal sheet.

[0053] In some embodiments, as shown in Figures 10a and 10b, two adjacent carbon brushes 76 along the axial direction F1 are arranged in a staggered pattern along the axial direction F1. This increases the circumferential span of all carbon brushes 76. When the slip ring 90 contacts all carbon brushes 76, the elastic elements 75 coupled to all carbon brushes 76 provide a wider angle of force application to the slip ring 90 and prevent the slip ring 90 from being pressed against the fixed end 751 by the elastic force of the elastic elements 75.

[0054] In some embodiments, as shown in Figure 5, the central angle of the circumferential span around the axis of projection of two axially adjacent carbon brushes 76 on a plane perpendicular to the axial direction F1 is equal to the central angle of the circumferential span around the axis of projection of all carbon brushes 76. As a result, all carbon brushes 76 are distributed in a relatively concentrated area along the circumferential direction, forming a structure in which they are alternately arranged in a staggered pattern. This is advantageous for improving the stability of the slip ring 90 when assembled by relatively unifying the angle at which the carbon brushes 76 apply force to the slip ring 90. In some embodiments, by using elastic elements 75 of uniform length and arranging adjacent elastic elements 75 alternately in a staggered pattern, the central angle around the axis of projection of two adjacent carbon brushes 76 can be made equal to the central angle of the circumferential span around the axis of projection of all carbon brushes 76. For example, if there are two brush assemblies 70, the two brush assemblies 70 can be arranged in a staggered pattern along the axial direction F1. This causes the elastic elements 75 of the two brush assemblies 70 to contact the slip ring 90 in different directions, resulting in a more stable slip ring 90 during rotation. When there are three brush assemblies 70, two adjacent brush assemblies 70 are staggered along the axial direction F1, while two spaced-out brush assemblies 70 are aligned along the axial direction F1. This arrangement ensures that the slip ring 90 always receives elastic force from each other during rotation, improving stability.

[0055] In some embodiments, as shown in Figures 3 and 14, the contact surfaces 761 of the carbon brushes 76 abut against the slip rings 90. Specifically, the contact surface 761 of each carbon brush 76 abuts against one of the conductive rings 91. Specifically, when the carbon brushes 76 are pressed by the slip rings 90, the deformation of the elastic elements 75 generates an elastic force on the carbon brushes 76, ensuring that the contact surfaces 761 of the carbon brushes 76 remain in contact with the conductive rings 91. In some embodiments, adjacent elastic elements 75 along the axial direction F1 are spaced apart from each other, thereby maintaining insulation between adjacent conductive rings 91.

[0056] In some embodiments, the carbon brush 76 is welded to the elastic element 75, which helps to ensure the stability and conductivity of the connection between the carbon brush 76 and the elastic element 75.

[0057] The elastic element 75 is substantially as shown in Figures 11a and 11b. The elastic element 75 can have the shape shown in TIFF2026512558000002.tif13150, but it can also have other shapes having multiple bends as shown in Figures 13 and 14. The present invention does not limit the specific shape of the elastic element 75. In some embodiments, as shown in Figures 9 and 11b, the elastic element 75 includes a bend section 753 and a sheet section 754 coupled to the bend section 753. The bend section 753 has greater rigidity than the sheet section 754. The free end 752 of the elastic element 75 is located on the bend section 753. The inside of the conductive sheet 73 forms a bend transition region 730. The portion of the sheet section 754 away from the bend section 753 is attached to the conductive sheet 73, while the portion of the sheet section 754 closer to the bend section 753 is separated from the conductive sheet 73 in the bend transition region 730. Specifically, the bent section 753 has a bent transition shape, and by setting the amplitude of the bent section 753, the angle of the carbon brush 76 relative to the fixed end 751 of the elastic element 75 can be adjusted. The bent section 753 has a more stable shape than the sheet section 754, and the carbon brush 76 is fixedly coupled to the bent section 753, so as a result, the contact area between the carbon brush 76 and the bent section 753 can be stably maintained. The portion of the sheet section 754 closest to the bent section 753 separates from the conductive sheet 73 in the bent transition region 730, so when the carbon brush 76 is pressed by the slip ring 90, that portion of the sheet section 754 undergoes curvilinear elastic deformation. Compared to angular elastic deformation of the sheet section 754, curvilinear elastic deformation allows the sheet section 754 to have better shape recovery, thereby enabling the carbon brush 76 to maintain more reliable contact with the slip ring 90.In some embodiments, the end of the conductive sheet 73 coupled to the elastic element 75 is bent away from the free end 752, thereby forming a bent transition region 730 inside the conductive sheet 73.

[0058] In some embodiments, as shown in Figure 9, the edges of the bent section 753 have a folded structure. In other embodiments, the thickness of the bent section 753 is greater than the thickness of the sheet section 754. Specifically, in the direction near the bent section 753, a portion of the sheet section 754 begins to separate from the conductive sheet 73 in the bend transition region 730. The shape of the end of the sheet section 754 is close to a straight shape. In some embodiments, the free end 752 of the elastic element 75 is bent away from the support 71. After the free end 752 of the elastic element 75 is bent away from the support 71, the distance between the free end 752 of the elastic element 75 and the inner surface of the support 71 increases, and the free end 752 of the elastic element 75 can make sufficient contact with the outer surface of the conductive ring 91, even if the distance between the conductive ring 91 and the support 71 is relatively large. This helps to increase the pressure between the free end 752 of the elastic element 75 and the conductive ring 91.

[0059] In some embodiments, as shown in Figures 5 and 10a, with respect to two adjacent elastic elements 75 along the axial direction F1, the fixed ends 751 of the two elastic elements 75 are positioned in a direction along the same diameter of the slip ring 90 (e.g., direction F4 as shown in Figure 10a). The carbon brushes 76 are positioned circumferentially between the two fixed ends 751. With respect to a projection on a plane perpendicular to the axial direction F1, the fixed ends 751 of the two adjacent elastic elements 75 are positioned in a direction along the same diameter of the slip ring 90. The slip ring 90 enters between the two fixed ends 751 along the intended mounting direction F2. The positioning of the fixed ends 751 of the two adjacent elastic elements 75 along the same diameter of the slip ring 90 increases the angle between the two adjacent carbon brushes 76 and the slip ring 90, thereby increasing the angular contact range between the slip ring 90 and all the carbon brushes 76. This arrangement prevents the slip ring 90 from slipping off the contact surface 761 of the carbon brush 76 due to a smaller support area during assembly, thereby improving the positional stability of the slip ring 90 during the assembly process.

[0060] In some embodiments, as shown in Figures 10a and 10b, in the free state of the elastic element 75, the direction from the fixed end 751 to the free end 752 is inclined toward the mounting portion 72 with respect to the relative direction F4 between the two fixed ends 751. Therefore, when assembling the slip ring 90, the slip ring 90 must first enter the relative space between the fixed ends 751 of two adjacent elastic elements 75, and then continue moving toward the mounting portion 72 along the intended assembly direction F2 before contacting the carbon brush 76. During the assembly process of the slip ring 90, the fixed ends 751 are in a stable position relative to the support 71 and thus play a certain limiting role to the slip ring 90, preventing the slip ring 90 from being pushed out by the elastic force of the elastic element 75 along the relative direction F4. In some embodiments, the distance between the two fixed ends 751 along the relative direction F4 is greater than the outer diameter of the slip ring 90.

[0061] In another embodiment, the distance between the two fixed ends 751 along the relative direction F4 may be smaller than the outer diameter of the slip ring 90. The fixed ends 751 and contact surfaces 761 of the two adjacent elastic elements 75 form an arc, the radius of curvature of which is at least the radius of the slip ring 90.

[0062] In some embodiments, as shown in Figures 5 and 11a, at least two conductive sheets 73 are arranged continuously along an axial direction F1. With respect to two adjacent conductive sheets 73 along the axial direction F1, the portions of the two conductive sheets 73 that connect to the fixed ends 751 are offset, and the conductive sheets 73 extend along a short path to the fixed ends 751 of the corresponding elastic elements 75. In the case of two conductive sheets 73 separated by one conductive sheet 73 along the axial direction F1, the portions of both conductive sheets 73 that connect to the fixed ends 751 are separated by a greater distance along the axial direction F1. This distance is at least greater than the dimensions of the conductive sheets 73 along the axial direction F1, ensuring insulation between the conductive sheets 73.

[0063] The embodiments described above are merely descriptions of preferred embodiments of the present application and do not limit the scope of the present application. Any modifications and improvements made by those skilled in the art to the technical solutions of the present application without departing from the spirit of the design should be included within the scope of protection as defined by the claims of the present application. [Explanation of Symbols]

[0064] 100 Internal rotor motor 20 Stator Housing 21 First recess 22 Opening 23 Side wall elements 30 Rotor Assembly 31 Rotating shaft 32 cores 33 coils 40 Conductive Devices 70 Brush Assembly 71 Support 72 Mounting part 721 Inner seat 720 Convex Ribs 722 Outer seat 723 Transition Section 724 Seat part 725 Positioning groove 726 Engagement Block 727 Engagement groove 728 First guide groove 729 Second guide groove 73 Conductive Sheet 730 Flexion transition area 731 Outer extension section 732 Lateral extension section 733 Longitudinal extension section 734 Pin Section 735 End 74 brush elements 75 Elastic elements 751 Fixed end 752 Free end 753 Bending section 754 Seat Section 76 Carbon Brushes 761 Contact surface 90 Slip Rings 91 Conductive ring 50 magnets 80 End cover 81 Bearing components 82 Second recess F1 Axial direction F2 Intended integration direction F3 Outward direction F4 Relative Direction

Claims

1. Support and At least two brush elements spaced apart in the axial direction, A brush assembly comprising, Each of the aforementioned brush elements comprises an elastic element and a carbon brush. Each elastic element comprises a fixed end fixedly connected to the support and a free end opposite to the fixed end. Each of the carbon brushes is fixed to the free end of the corresponding elastic element and has a contact surface for sliding contact with the slip ring. A brush assembly in which the outward direction of the contact surface facing outward from the carbon brush avoids the support and all of the elastic elements.

2. On a plane perpendicular to the axial direction, the first central angle corresponding to all projections of the free end is not greater than the second central angle corresponding to all projections of the fixed end. The brush assembly according to claim 1, wherein the first central angle is the central angle of the span of all projections of the free end in the circumferential direction about the axis, the second central angle is the central angle of the span of all projections of the fixed end in the circumferential direction about the axis, and the axis is the projection of the central axis of the slip ring on a plane perpendicular to the axial direction when the carbon brush is combined with the slip ring.

3. The brush assembly according to claim 2, wherein the two carbon brushes adjacent in the axial direction are arranged in a staggered pattern in the axial direction.

4. The brush assembly according to claim 3, wherein, on a plane perpendicular to the axial direction, the central angle of the projections of the two axially adjacent carbon brushes about the axis is equal to the central angle of the span of all the projections of the circumferential carbon brushes about the axis.

5. The brush assembly according to claim 1 or 2, wherein the support has a mounting portion and a support portion, one end of the support portion is connected to the mounting portion, the other end of the support portion is connected to the fixed end of the elastic element, and the distance between the free end and the mounting portion is smaller than the distance between the fixed end and the mounting portion.

6. The brush assembly according to claim 5, wherein the side surface of the mounting portion is provided with a first guide groove, the first guide groove being configured for axial guidance and radial restriction when the brush assembly is mounted in a first recess of the stator housing.

7. The brush assembly according to claim 5, wherein the mounting portion is provided with a second guide groove, and the second guide groove is configured for radial guidance and axial restriction when the brush assembly is coupled to the second recess of the end cover.

8. The brush assembly according to claim 5, wherein the mounting portion comprises at least two axially adjacent seat portions, each of which engages with an adjacent seat portion, and the support portion comprises at least two conductive sheets, each of which one end penetrates one of the seat portions, and each of which the other end is coupled to the fixed end of the elastic element.

9. The brush assembly according to claim 8, wherein each of the seat portions is provided with a positioning groove, and each of the conductive sheets is at least partially inserted into the positioning groove of the corresponding seat portion.

10. slip rings and A brush assembly according to any one of claims 1 to 9, A conductive device, The slip ring is a conductive device comprising at least two conductive rings insulated from each other, wherein the contact surface of each of the carbon brushes abuts against one of the conductive rings.

11. An internal rotor motor comprising a stator assembly and a rotor assembly rotatably disposed within the stator assembly, The stator assembly comprises a stator housing, a magnet disposed on the inner wall of the stator housing, and a brush assembly according to any one of claims 1 to 9. The magnet forms a steady magnetic field with respect to the stator housing. The rotor assembly comprises a core, a rotating shaft inserted into the core, and a coil wound around the core. The rotating shaft is sleeved with a slip ring electrically connected to the coil, and the contact surface of the brush assembly abuts against the slip ring. Internal rotor motor.

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