Motor core with straight laminated core bended

Abstract

Disclosed herein a bending motor core formed by bending a straight laminated core 3 in which N unit split cores 3-1, 3-2,..., 3-N having a yoke 31 and a tooth 32 are connected in a straight line, wherein the yoke 31 comprises a first bonding part 33 formed at one end and a second bonding part 34 formed at another end, the first bonding part 33 of one unit split core and the second bonding part 34 of another unit split core adjacent to the unit split core are inserted into and bonded with each other by bending the straight laminated core 3, and the straight laminated core 3 is formed by alternately laminating a first straight core sheet 1 and a second straight core sheet 2.

Description

MOTOR CORE WITH STRAIGHT LAMINATED CORE BENDED

[0001] The present invention relates to a motor core. More specifically, the present invention relates to a motor core capable of facilitating bonding with adjacent unit cores and accomplishing adhesion between adjacent unit cores by thermosetting when manufacturing a circular motor core by bending while a plurality of split cores divided into individual slots are connected.

[0002] In general, a motor includes a stator and a rotor, and the stator or rotor is made from a motor core manufactured by laminating a plurality of thin electric steel sheets.

[0003] Such a motor core is manufactured by successive forming and laminating of electric steel sheets by a press process. A conventional motor core is disclosed in Korean Patent No. 10-2644795. This prior art discloses a stator formed by bonding an insulator with a unit split core consisting of a yoke and a tooth and winding coils thereto, and then bonding the plurality of unit split cores in succession. Such a stator has a disadvantage that the manufacturing process is complicated because each unit split core should be bonded one by one, and the ends of the pair of coils should all be wired together for each unit split core.

[0004] Meanwhile, Korean Patent No. 10-2461192 and Japanese Patent Laid-Open No. 2009-278814 disclose a rolling-type motor core (or "a bending motor core") manufactured by bending a straight laminated core in which a plurality of unit split cores are connected in a straight line into a circle. When manufacturing a rolling-type motor core by applying this straight laminated core, higher winding speeds, higher winding volumes, and higher dropout rates may be achieved when winding coils on the tooth, and fewer processes may be used than the existing unit split core.

[0005] However, the conventional straight laminated core has a disadvantage that the operation efficiency of the motor is reduced because the bonding between the laminated core sheets is made by inter-locking due to the embossed shape, which causes iron loss of the motor core.

[0006] In addition, the bonding between two adjacent yokes in a split core is only achieved by caulking or mechanical bonding of a protrusion-groove structure, which leads to increased manufacturing processes or reduced quality of a product.

[0007] Accordingly, in order to overcome the above-mentioned problems, the present inventor suggests a bending motor core capable of simplifying the manufacturing process and increasing the efficiency of the motor by excluding mechanical bonding such as embossing in the bonding between core sheets when manufacturing a bending core.

[0008] It is an object of the present invention to provide a bending motor core with a novel structure.

[0009] It is another object of the present invention to provide a bending motor core capable of excluding mechanical bonding between core sheets and reducing the number of manufacturing processes.

[0010] It is yet another object of the present invention to provide a bending motor core capable of increasing the efficiency of the motor and simplifying the manufacturing process.

[0011] The above and other inherent objects of the present invention may all be easily achieved by the description of the present invention described below.

[0012] A bending motor core according to the present invention is formed by bending a straight laminated core 3 in which N unit split cores 3-1, 3-2, ..., 3-N having a yoke 31 and a tooth 32 are connected in a straight line,

[0013] wherein the yoke 31 comprises a first bonding part 33 formed at one end and a second bonding part 34 formed at another end, the first bonding part 33 of one unit split core and the second bonding part 34 of another unit split core adjacent to the unit split core are inserted into and bonded with each other by bending the straight laminated core 3, and the straight laminated core 3 is formed by alternately laminating a first straight core sheet 1 and a second straight core sheet 2.

[0014] In the present invention, the first straight core sheet 1 is formed by N first unit core sheets 1-1, 1-2, ..., 1-N connected in succession, and the second straight core sheet 2 is formed by N second unit core sheets 2-1, 2-2, ..., 2-N connected in succession.

[0015] In the present invention, the first unit core sheet 1-N consists of a first yoke 11 and a first tooth 12, and the second unit core sheet 2-N consists of a second yoke 21 and a second tooth 22, the first bonding part 33 is formed by alternately laminating a first protrusion 13 formed at one end of the first yoke 11 and a first groove 14 formed at another end of the first yoke 11, and the second bonding part 34 is formed by alternately laminating a second groove 23 formed at one end of the second yoke 21 and a second protrusion 24 formed at another end of the second yoke 21.

[0016] In the present invention, the first unit core sheet 1-N and the second unit core sheet 2-N are self-bonding SB steel sheets.

[0017] In the present invention, the adhesive is applied to a surface of the first unit core sheet 1-N and the second unit core sheet 2-N to be adhered to each other.

[0018] In the present invention, the straight laminated core 3 consists of two or more bending M-split cores 10-1, 10-2, ..., 10-M.

[0019] The present invention provides a bending motor core capable of excluding mechanical bonding between core sheets and reducing the number of manufacturing processes.

[0020] In addition, the present invention increases the efficiency of the motor and simplifying the manufacturing process.

[0021] Fig. 1 is a plan view illustrating first and second straight core sheets for manufacturing a bending motor core according to the present invention;

[0022] Fig. 2 is a conceptual diagram illustrating a form of laminating first and second straight core sheets in the process of manufacturing a bending motor core according to the present invention;

[0023] Fig.3 is a plan view illustrating a straight laminated core manufactured by alternately laminating first and second straight core sheets for manufacturing a bending motor core according to the present invention;

[0024] Fig. 4 is a conceptual diagram illustrating a process of bending a straight laminated core for manufacturing a bending motor core according to the present invention;

[0025] Fig. 5 is a plan view illustrating a bending motor core according to the present invention; and

[0026] Fig. 6 is a conceptual diagram illustrating another example of manufacturing a bending motor core by using bending 4-split cores according to another example of the present invention.

[0027] Hereinafter, the present invention will be explained in detail with reference to the accompanying drawings.

[0028] Fig. 1 is a plan view illustrating first and second straight core sheets 1, 2 for manufacturing a bending motor core according to the present invention, Fig. 2 is a conceptual diagram illustrating a form of laminating first and second straight core sheets 1, 2 in the process of manufacturing a bending motor core according to the present invention, Fig.3 is a plan view illustrating a straight laminated core manufactured by alternately laminating first and second straight core sheets 1, 2 for manufacturing a bending motor core 10 according to the present invention, Fig. 4 is a conceptual diagram illustrating a process of bending a straight laminated core 3 for manufacturing a bending motor core 10 according to the present invention, and Fig. 5 is a plan view illustrating a bending motor core 10 according to the present invention.

[0029] As illustrated in Figs. 1 to 5, the bending more core 10 according to the present invention is manufactured by bending a straight laminated core 3 manufactured by alternately laminating a first straight core sheet 1 and a second straight core sheet 2.

[0030] In the first straight core sheet 1, a plurality of first unit core sheets 1-1, 1-2, ..., 1-N are connected in succession in a straight line. In the present invention, N is a natural number greater than or equal to 2, and Figs. 1 to 5 illustrate a case where N is 11.

[0031] Each first unit core sheet 1-N forming the first straight core sheet 1 consists of a first yoke 11 and a first tooth 12 protruding downwardly or upwardly from a central portion of the first yoke 11. The first yoke 11 and the first tooth 12 have a 'T' shape when viewed in a plan. Figs. 1 to 3 illustrate a shape in which the first tooth 12 protrudes downwardly from a central portion of the first yoke 11. This shape is applicable to an inner rotor-type motor in which a rotor rotates inside a stator. Of course, the present invention is also applicable to an outer rotor-type motor having a shape in which the first tooth 12 protrudes upwardly from a central portion of the first yoke 11.

[0032] The first straight core sheet 1 comprises a 1stfirst unit core sheet 1-1 to a last first unit core sheet 1-N connected in succession in a straight line. Fig. 1 illustrates a shape in which a 1stfirst unit core sheet 1-1 to a 11thfirst unit core sheet 1-11 are connected in succession.

[0033] At one end (left side in Fig. 1) of the first yoke 11 of each first unit core sheet 1-N, a first protrusion 13 is protrudingly formed, and at another end (right side in Fig. 1) of the first yoke 11, a first groove 14 is formed to have a recessed shape corresponding to the first protrusion 13. In Fig. 1, a first protrusion 13 is formed at a left end of the first yoke 11 of the first unit core sheet 1-N, and a first groove 14 is formed at a right end thereof.

[0034] A first protrusion-side connection part 13a is formed at an upper side of the first protrusion 13, and a first protrusion-side contact part 13b is formed at a lower side thereof. A first groove-side connection part 14a is formed at an upper side of the first groove 14, and a first groove-side contact part 14b is formed at a lower side thereof. As illustrated in Fig. 1, the first groove-side connection part 14a of the 1stfirst unit core sheet 1-1 and the first protrusion-side connection part 13a of the 2ndfirst unit core sheet 1-2 are connected to each other. In other words, assuming that n is a natural number, the first groove-side connection part 14a of the nthfirst unit core sheet 1-n and the first protrusion-side connection part 13a of the (n+1)thfirst unit core sheet 1-(n+1) are connected to each other. The first protrusion-side connection part 13a of the 1stfirst unit core sheet 1-1 and the first groove-side connection part 14a of the last first unit core sheet 1-11 contact each other in a final bending motor core product.

[0035] The first groove-side contact part 14b of the 1stfirst unit core sheet 1-1 and the first protrusion-side connection part 13a of the 2ndfirst unit core sheet 1-2 contact each other after bending. The first groove-side contact part 14b of the nthfirst unit core sheet 1-n and the first protrusion-side contact part 13b of the (n+1)thfirst unit core sheet 1-(n+1) contact each other after bending. In Fig. 1, the first protrusion-side contact part 13b of the 1stfirst unit core sheet 1-1 and the first groove-side contact part 14b of the last first unit core sheet 1-11 contact each other in a final bending motor core product.

[0036] A second straight core sheet 2 has a mirror image shape symmetrical to the first straight core sheet 1, i.e., they have opposite right and left sides. Each second unit core sheet 2-N forming the second straight core sheet 2 consists of a second yoke 21 and a second tooth 22 protruding downwardly or upwardly from a central portion of the second yoke 21. The second yoke 21 and the second tooth 22 have a 'T' shape when viewed in a plan.

[0037] The second straight core sheet 2 comprises a 1stsecond unit core sheet 2-1 to anNthsecond unit core sheet 2-N connected in succession in a straight line. Fig. 1 illustrates a shape in which a second unit core sheet 2-1 to a second core sheet 2-11, i.e., 11 sheets are connected in succession.

[0038] At one end (left side in Fig. 1) of the second yoke 21 of each second unit core sheet 2-N, a second groove 23 is formed in a recessed shape, and at another end (right side in Fig. 1) of the second yoke 21, a second protrusion 24 is formed to have a protruding shape corresponding to the second groove 23. In Fig. 1, a second groove 23 is formed at a left end of the second yoke 21 of the second unit core sheet 2-N, and a second protrusion 24 is formed at a right end thereof.

[0039] A second groove-side connection part 23a is formed at an upper side of the second groove 23, and a second groove-side contact part 23b is formed at a lower side thereof. A second protrusion-side connection part 24a is formed at an upper side of the second protrusion 24, and a second protrusion-side contact part 24b is formed at a lower side thereof. As illustrated in Fig. 1, the second protrusion-side connection part 24a of the 1stsecond unit core sheet 2-1 and the second groove-side connection part 23a of the 2ndsecond unit core sheet 2-2 are connected to each other. In other words, assuming that n is a natural number, the second protrusion-side connection part 24a of the nthsecond unit core sheet 2-n and the second groove-side connection part 23a of the (n+1)thsecond unit core sheet 2-(n+1) are connected to each other. The second groove-side connection part 23a of the 1stsecond unit core sheet 2-1 and the second protrusion-side connection part 24a of the final second unit core sheet 2-11 contact each other in a final bending motor core product.

[0040] The second protrusion-side contact part 24b of the 1stsecond unit core sheet 2-1 and the second groove-side connection part 23a of the 2ndsecond unit core sheet 2-2 contact each other after bending. The second protrusion-side contact part 24b of the nthsecond unit core sheet 2-n and the second protrusion-side contact part 24b of the (n+1)thsecond unit core sheet 2-(n+1) at a right side thereof contact each other after bending. In Fig. 1, the second groove-side contact part 23b of the 1stsecond unit core sheet 2-1 and the second protrusion-side contact part 24b of the final second unit core sheet 2-11 contact each other in a final bending motor core product.

[0041] Such a first straight core sheet 1 and a second straight core sheet 2 are formed by a successive press process of thin electric steel sheets. As illustrated in Fig. 2(b), a second straight core sheet 2 is formed and laminated on a first straight core sheet 1 formed as illustrated in Fig. 2(a), and then the first straight core sheet 1 and the second straight core sheet 2 are alternately and repeatedly laminated thereon to a certain height to manufacture a straight laminated core 3 as illustrated in Fig. 2(c). In other words, the straight laminated core 3 has a structure in which a predetermined number of first straight core sheets 1 and second straight core sheets 2 are alternately laminated. In this case, the first straight core sheet 1 and the second straight core sheet 2 may be alternately laminated one by one as illustrated in Fig. 2, or may be alternately laminated in batches of two, such as laminating two first straight core sheets 1 and laminating two sheets of second straight core sheets 2 thereon. In other words, each straight core sheet 1, 2 may be alternately laminated in batches of two or more.

[0042] The first straight core sheet 1 and the second straight core sheet 2 are formed by a successive press process of thin electric steel sheets, and these two straight core sheets 1, 2 should be adhered to each other while being laminated. Adhesion between the straight core sheets may be accomplished by the application of an adhesive, or by the use of a self-bonding electric steel sheet (hereinafter, referred to as "SB steel sheet") where an adhesive layer is coated on a surface of the electric steel sheet. In either case, the straight core sheets first accomplish preliminary adhesion between the sheets by applying constant heat or pressure while being formed and laminated in a press device, and then accomplish a complete bond by thermosetting in a heating device after the bending motor core is manufactured.

[0043] As illustrated in Fig. 3, the straight laminated core 3 has a structure in which N core split cores 3-N are connected in succession in a straight line. Each unit split core 3-N consists of a yoke 31 and a tooth 32, and one end (left side in Fig. 3) of the yoke 31 is a first bonding part 33, and another end thereof (right side in Fig. 3) is a second bonding part 34. The first bonding part 33 is a portion formed by alternately laminating the first protrusion 13 and the second groove 23. The second bonding part 34 is a portion formed by alternately laminating the first groove 14 and the second protrusion 24. The first bonding part 33 of one unit split core 3-N is inserted into and bonded with the second bonding part 34 of an adjacent unit split core 3-(N+1). However, as illustrated in Fig. 3, the first bonding part 33 of the 1stunit split core 3-1 is inserted into and bonded with the second bonding part 34 of the last 11thunit split core 3-11 after bending.

[0044] A first bonding part-side connection part 33a is formed at an upper side of the first bonding part 33 of one unit split core 3-N, and a first bonding part-side contact part 33b is formed at a lower side thereof. The first bonding part-side connection part 33a is a portion formed by alternately laminating the first protrusion-side connection part 13a of the first unit core sheet 1-N and the second groove-side connection part 23a of the second unit core sheet 2-N. The first bonding part-side contact part 33b is a portion formed by alternately laminating the first protrusion-side contact part 13b of the first unit core sheet 1-N and the second groove-side contact part 23b of the second unit core sheet 2-N.

[0045] Similarly, a second bonding part-side connection part 34a is formed at an upper side of the second bonding part 34 of the unit split core 3-N, and a second bonding part-side contact part 34b is formed at a lower side thereof. The second bonding part-side connection part 34a is a portion formed by alternately laminating the first groove-side connection part 14a of the first unit core sheet 1-N and the second protrusion-side connection part 24a of the second unit core sheet 2-N. The second bonding part-side contact part 34b is a portion formed by alternately laminating the second groove-side contact part 14b of the first unit core sheet 1-N and the second protrusion-side contact part 24b of the second unit core sheet 2-N.

[0046] With the straight laminated core 3 in which N unit split cores 3-N having such a structure are connected in succession, a circular bending motor core 10 may be manufactured by a bending process as illustrated in Fig. 4. The bending motor core 10 is illustrated in Fig. 5.

[0047] The bending motor core 10 has a structure in which the first bonding part 33 and second bonding part 34 of two adjacent unit split cores 3-N are inserted and bonded with each other. In this case, the second bonding part 34 of one unit split core 3-1 is bonded with the first bonding part 33 of the adjacent unit split core 3-2. Additionally, the second bonding part-side contact part 34b of one unit split core 3-1 contacts the first bonding part-side contact part 33b of the adjacent unit split core 3-2. The first bonding part 33 of the 1stunit split core 3-1 is bonded with the second bonding part 34 of the last 11thunit split core 3-11. The first bonding part-side connection part 33a of the 1stunit split core 3-1 contacts the second bonding part-side connection part 34a of the last 11thunit split core 3-11. Also, the first bonding part-side contact part 33b of the 1stunit split core 3-1 contacts the second bonding part-side contact part 34b of the last 11thunit split core 3-11.

[0048] Fig. 6 is a conceptual diagram illustrating another example of manufacturing a bending motor core 10' by using bending 4-split cores 10-1, 10-2,..., 10-4 according to another example of the present invention.

[0049] While the bending motor core 10 explained with reference to Fig. 4 is manufactured by bending one straight laminated core, the bending motor core 10' illustrated in Fig. 6 is manufactured by bonding four bending 4-split cores 10-1, 10-2, 10-3, 10-4. Fig. 6 illustrates an example of splitting the bending motor core 10 into four pieces, but any number of bending cores, such as two or more, may be selected and applied as appropriate. In this case, one bending motor core 10' may be manufactured by splitting into M bending M-split cores 10-1, 10-2, ..., 10-M (here, M is a natural number greater than or equal to 2). Such form of bending motor core 10' may be applied to large-scale motors with large size and power.

[0050] It should be noted that the description of the present invention described above is merely an example for understanding the present invention, and is not intended to limit the scope of the present invention. It should be construed that the scope of the present invention is defined by the appended claims, and all modifications and alternations of the present invention fall within the protection scope of the present invention.

Claims

1.A bending motor core formed by bending a straight laminated core 3 in which N unit split cores 3-1, 3-2, ..., 3-N having a yoke 31 and a tooth 32 are connected in a straight line, wherein the yoke 31 comprises a first bonding part 33 formed at one end and a second bonding part 34 formed at another end, the first bonding part 33 of one unit split core and the second bonding part 34 of another unit split core adjacent to the unit split core are inserted into and bonded with each other by bending the straight laminated core 3, and the straight laminated core 3 is formed by alternately laminating a first straight core sheet 1 and a second straight core sheet 2.2.The bending motor core of claim 1, the first straight core sheet 1 being formed by N first unit core sheets 1-1, 1-2, ..., 1-N connected in succession, and the second straight core sheet 2 is formed by N second unit core sheets 2-1, 2-2, ..., 2-N connected in succession.3.The bending motor core of claim 2, wherein the first unit core sheet 1-N consists of a first yoke 11 and a first tooth 12, and the second unit core sheet 2-N consists of a second yoke 21 and a second tooth 22, the first bonding part 33 is formed by alternately laminating a first protrusion 13 formed at one end of the first yoke 11 and a first groove 14 formed at another end of the first yoke 11, and the second bonding part 34 is formed by alternately laminating a second groove 23 formed at one end of the second yoke 21 and a second protrusion 24 formed at another end of the second yoke 21.4.The bending motor core of claim 3, wherein first unit core sheet 1-N and the second unit core sheet 2-N are self-bonding SB steel sheets.5.The bending motor core of claim 3, wherein an adhesive is applied to a surface of the first unit core sheet 1-N and the second unit core sheet 2-N to be adhered to each other.6.The bending motor core of any one of claims 1 to 5, wherein the straight laminated core 3 consists of two or more bending M-split cores 10-1, 10-2, ..., 10-M.

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