Spiral motor core

Abstract

Disclosed herein is a spiral motor core having a structure in which first to Nth laminations L1, L2,..., LN connected to each other sequentially are wound and circularly laminated, wherein the first to Nth laminations L1, L2,..., LN do not have embossing or holes formed, and the bonding between two adjacent laminations among the first to Nth laminations L1, L2,..., LN is achieved by curing of an adhesive or an adhesive coating layer (here, N is a natural number greater than or equal to 2).

Description

SPIRAL MOTOR CORE

[0001] The present invention relates to a motor core. More specifically, the present invention relates to a motor core capable of improving the quality of a spiral motor core that is wound and laminated in a spiral shape and increasing the efficiency of motor operation.

[0002] In general, a motor comprises a stator and a rotor. The stator or rotor comprises a stator core or a rotor core manufactured by laminating laminar members made by molding thin electrical steel strips. Motor core is a collective term for a stator core or a rotor core.

[0003] As such, there are various types of motor cores manufactured by laminating laminar members, among which US Patent No. 4,395,815 and Korean Patent No. 10-1275210 disclose a motor core manufactured by winding a base material in a spiral shape. As such, motor cores manufactured by winding a base material linearly supplied in succession are referred to by terms such as spiral motor core or helical motor core.

[0004] Such spiral motor cores are still widely used today because they have the advantage of reducing the amount of scrap discarded during the press molding process, as a pressing device supplies a linearly molded base material and winds the same to manufacture a circular motor core.

[0005] The spiral motor cores disclosed in the two prior arts are manufactured by laminating a base material obtained by molding an electrical steel sheet in a pressing device in succession and winding the same in a rotating winding jig. In other words, the spiral motor core is manufactured by going through successive lamination processes by winding a base material molded in a pressing device in succession in a rotating jig. The base material first supplied to the winding jig rotates once to complete a circular lamination, and another lamination is laminated on top of the circular lamination after the second rotation. When manufacturing a motor core with ten layers of laminations, the base material is wound ten times in the winding jig to manufacture a single spiral motor core with ten layers of laminations.

[0006] In this case, one lamination and the lamination laminated on top thereof must be bonded together. For such bonding, US Patent No. 4,395,815 discloses bonding a rivet in a hole formed in each lamination to form a bonding between the laminations. In Korean Patent No. 10-1275210, an embossing is formed on each unit core configuring a lamination, and the embossing is interlocked between the upper and lower laminations by an interlocking method to form a bonding between the laminations.

[0007] However, such bonding between laminations using rivets or embossing causes iron loss and loss of magnetic flux density due to the hole or embossed shape formed in the lamination, which reduces the efficiency of the motor, reduces the dropping rate, and causes vibration noise due to resonance.

[0008] In order to solve the above problems, the present inventor suggests a spiral motor core with a new structure capable of achieving a bonding between laminations without holes or embossing for riveting.

[0009] It is an object of the present invention to provide a spiral motor core enabling a firm bonding between laminations without holes or embossing for riveting through the new structure.

[0010] It is another object of the present invention to provide a spiral motor core capable of increasing productivity and efficiency of the motor.

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

[0012] A spiral motor core having a structure in which first to Nthlaminations L1, L2, ..., LNconnected to each other sequentially are wound and circularly laminated,

[0013] wherein the first to Nthlaminations L1, L2, ..., LNdo not have embossing or holes formed, and the bonding between two adjacent laminations among the first to Nthlaminations L1, L2, ..., LNis achieved by curing of an adhesive or an adhesive coating layer (here, N is a natural number greater than or equal to 2).

[0014] In the present invention, the first to Nthlaminations L1, L2, ..., LNare formed by molding a SB electrical steel sheet.

[0015] In the present invention, each of the first to Nthlaminations L1, L2, ..., LNare formed by connecting first to Mthunit cores T1, T2, ..., TM-1, TM,

[0016] wherein among the first to Nthlaminations L1, L2, ..., LN, the first to (M-1)thunit cores T1, T2, ..., TM-1of an odd numbered lamination L2k-1is a first base core 10, and the Mthunit core TMis a first transition core 20, and

[0017] among the first to Nthlaminations L1, L2, ..., LN, the first to (M-1)thunit cores T1, T2, ..., TM-1of an even numbered lamination L2kis a second base core 30, and the Mthunit core TMis a second transition core 40 (here, k is a natural number).

[0018] In the present invention, the first base core 10, the first transition core 20, the second base core 30, and the second transition core 40 have yokes 11, 21, 31, 41, and teeth 12, 22, 32, 42 formed by protruding to inner or outer circumference sides of the yokes.

[0019] In the present invention, the first base core 10 comprises a first directional connection 13 formed on an outer circumference side of a first directional end of the yoke 11, a first directional protrusion 14 formed on a first directional end of the yoke 11, a second directional connection 15 formed on an outer circumference side of a second directional end of the yoke 11, and a second directional groove 16 formed on a second directional end of the yoke 11.

[0020] In the present invention, the first transition core 20 comprises a first directional connection 23 formed on an outer circumference side of a first directional end of the yoke 21, a first directional protrusion 24 formed on a first directional end of the yoke 21, a second directional connection 25 formed on an outer circumference side of a second directional end of the yoke 21, and a second directional protrusion 26 formed on a second directional end of the yoke 21.

[0021] In the present invention, the second base core 30 comprises a first directional connection 33 formed on an outer circumference side of a first directional end of the yoke 31, a first directional groove 34 formed on a first directional end of the yoke 31, a second directional connection 35 formed on an outer circumference side of a second directional end of the yoke 31, and a second directional protrusion 36 formed on a second directional end of the yoke 31.

[0022] In the present invention, the second transition core 40 comprises a first directional connection 43 formed on an outer circumference side of a first directional end of the yoke 41, a first directional groove 44 formed on a first directional end of the yoke 41, a second directional connection 45 formed on an outer circumference side of a second directional end of the yoke 41, and a second directional groove 46 formed on a second directional end of the yoke 41.

[0023] The present invention provides a spiral motor core enabling a firm bonding between laminations without holes or embossing for riveting through the new structure, and also provides a spiral motor core capable of increasing productivity and efficiency of the motor.

[0024] Fig. 1 is a plan view illustrating a spiral motor core according to the present invention;

[0025] Fig. 2 is a conceptual diagram illustrating a process for manufacturing a spiral motor core according to the present invention;

[0026] Fig. 3 is an enlarged view of a portion of Fig. 2;

[0027] Fig. 4 is a perspective view illustrating a process for manufacturing a spiral motor core according to the present invention;

[0028] Fig. 5 is a plan view illustrating the first and second laminations configuring a spiral motor core according to the present invention; and

[0029] Fig. 6 is a conceptual diagram illustrating connections of the first to third laminations configuring a spiral motor core according to the invention.

[0030] Hereinafter, the present invention will be explained in detail with reference to the accompanying drawings.

[0031] Fig. 1 is a plan view illustrating a spiral motor core 1 according to the present invention. Fig. 2 is a conceptual diagram illustrating a process for manufacturing a spiral motor core 1 according to the present invention. Fig. 3 is an enlarged view of a portion of Fig. 2. Fig. 4 is a perspective view illustrating a process for manufacturing a spiral motor core 1 according to the present invention. Fig. 5 is a plan view illustrating the first and second laminations L1, L2configuring a spiral motor core 1 according to the present invention. Fig. 6 is a conceptual diagram illustrating connections of the first to third laminations L1, L2, L3configuring a spiral motor core 1 according to the invention.

[0032] Referring to Figs. 1 to 6 together, the spiral motor core 1 according to the present invention is manufactured by circularly winding a base material 100 in which N laminations L1, L2, ..., LNare connected in succession.

[0033] The base material 100 for manufacturing a spiral motor core 1 according to the present invention is manufactured by linearly processing a thin iron sheet referred to as an electrical steel sheet or a silicon steel sheet by press molding. The linearly processed base material 100 is supplied to a rotating winding device (not shown) and laminated while being circularly wound to manufacture a spiral motor core 1.

[0034] In order to manufacture a spiral motor core 1 laminated in N layers by N windings, the base material 100 has a structure in which first to Nthlaminations L1, L2, ..., LNconnected in succession are connected sequentially in a row. Here, N is a natural number greater than or equal to 2 and may be applied in various numbers according to the specification of the final motor core product. Fig. 4 illustrates a state in which twelve laminations L1, L2, ..., L12are wound and laminated.

[0035] Each lamination LNcomprises M unit cores T1, T2, ..., TMthat are sequentially connected. Here, M is a natural number greater than or equal to 2 and may vary according to the specification of the final motor core product. For the sake of convenience in explanation, Figs. 1 to 6 illustrate a case in which M is 12, i.e., a case in which first to twelfth unit cores T1, T2, ..., TMare applied, but the number of unit cores is not necessarily limited thereto, and the number of unit cores may vary according to design need or product specification.

[0036] The conventional spiral motor core has unit cores with the same shape, but the present invention is characterized by applying four types of unit cores with different shapes. In the prior art, a groove is provided between the unit cores to wind the base material so that the lamination has a circular shape, but there is a problem that the connecting parts between adjacent unit cores are bent or deformed when winding circularly. This is because the connecting parts between the unit cores have a relatively large width. To solve this problem, processes such as heating the base material during winding to thermally deform the connecting parts have been applied. The present invention solves the above problem by thinning the connecting parts between the unit cores without such a process, while forming the connecting parts separately after being circularly wound.

[0037] In the first place, a first lamination L1comprises M unit cores, wherein M-1 first base cores 10 composed of first to (M-1)thunit cores T1, T2, ..., TM-1are connected in succession, and the last Mthunit core TMis a first transition core 20. A second lamination L2comprises M unit cores, wherein M-1 second base cores 30 composed of first to (M-1)thunit cores T1, T2, ..., TM-1are connected in succession, and one M unit core TMis a second transition core 40. Figs. 1 to 6 illustrate an Nthlamination LNwhere M is 12. Thus, a first lamination L1comprises eleven first base cores 10 and one first transition core 20 connected in succession, and a second lamination L2comprises eleven second base cores 30 and one second transition core 40 connected in succession.

[0038] A third lamination L3has the same unit core combination as the first lamination L1, and a fourth lamination L4has the same unit core combination as the second lamination L2. As such, odd numbered laminations and even numbered laminations have the same unit core combination, resulting in a laminated structure having N first to Nthlaminations LNwound together.

[0039] A first base core 10, a first transition core 20, a second base core 30, and a second transition core 40 have yokes 11, 21, 31, 41 and teeth 12, 22, 32, 42 formed by protruding to inner or outer circumference sides of the yokes. Figs. 1 to 6 illustrate a state in which the teeth 12, 22, 32, 42 protrude to an inner circumference side of the yokes 11, 21, 31, 41, but the shape is not necessarily limited thereto, and the yokes 11, 21, 31, 41 may be configured to protrude to an outer circumference side of the teeth 12, 22, 32, 42. When a spiral motor core 1 is a stator core, the spiral motor core 1 illustrated in Figs. 1 to 6 is an inner rotor type stator core where the rotor is located on an inner side of the stator, and the configuration in which the yokes 11, 21, 31, 41 protrude to an outer circumference side of the teeth 12, 22, 32, 42 is an outer rotor type stator core where the motor is located on an outer side of the stator.

[0040] As illustrated in (A) of Fig. 5, a first lamination L1has a structure in which eleven first base cores 10 and one first transition core 20 are connected sequentially. As illustrated in (A) of Fig. 6, a first base core 10 comprises a yoke 11, a tooth 12 formed to protrude to an inner circumference side of the circular lamination from the yoke 11, a first directional connection 13 formed on an outer circumference side of a first directional end of the yoke 11, a first directional protrusion 14 formed on a first directional end of the yoke 11, a second directional connection 15 formed on an outer circumference side of a second directional end of the yoke 11, and a second directional groove 16 formed on a second directional end of the yoke 11. As used herein, "first direction" refers to a direction in which the base material 100 is supplied, i.e., the direction of the arrow in Fig. 5, and "second direction" refers to an opposite direction of the first direction, i.e., the direction opposite the arrow in Fig. 5.

[0041] A first directional connection 13 is a part connected to a second directional connection 15 of a first base core 10 adjacent in the first direction. A first directional protrusion 14 is a part formed by protruding from a first directional end of the yoke 11 in the first direction. A second directional connection 15 is a part formed on an outer circumference side of a second directional end of the yoke 11 to be connected to a first directional connection 13 of a first base core 10 adjacent in the second direction. A second directional groove 16 is a part having a grooved shape toward the first direction on a second directional end of the yoke 11. A second directional groove 16 has an engaged shape after winding with a first directional protrusion 14 of a first base core 10 adjacent in the second direction.

[0042] A first transition core 20 is a twelfth unit core T12of a first lamination L1, which is the unit core connected to a first unit core T1of the second lamination L2. As illustrated in (A) of Fig. 6, a first transition core 20 comprises a yoke 21, a tooth 22 formed to protrude to an inner circumference side of the circular lamination from the yoke 21, a first directional connection 23 formed on an outer circumference side of a first directional end of the yoke 21, a first directional protrusion 24 formed on a first directional end of the yoke 21, a second directional connection 25 formed on an outer circumference side of a second directional end of the yoke 21, and a second directional protrusion 26 formed on a second directional end of the yoke 21. A first directional connection 23 of the first transition core 20 is connected to a second directional connection 15 of a first base core 10, which is an eleventh unit core T11. A second directional connection 25 of a first transition core 20 is connected to a first directional connection 33 of a second base core 30, which is a first unit core T1of the second lamination L2.

[0043] The first base core 10 and the first transition core 20 of such structure are connected in succession to form a first lamination L1, and a second lamination L2is connected thereto in the second direction of the first lamination L1.

[0044] As illustrated in (B) of Fig. 5, a second lamination L2has a structure in which eleven second base cores 30 and one second transition core 40 are connected sequentially.

[0045] The second base core 30 has a mirror image structure symmetrical to the first base core 10. As illustrated in (B) of Fig. 6, a second base core 30 comprises a yoke 31, a tooth 32 formed to protrude to an inner circumference side of the circular lamination from the yoke 31, a first directional connection 33 formed on an outer circumference side of a first directional end of the yoke 31, a first directional groove 34 formed on a first directional end of the yoke 31, a second directional connection 35 formed on an outer circumference side of a second directional end of the yoke 31, and a second directional protrusion 36 formed on a second directional end of the yoke 31.

[0046] A first directional connection 33 is a part connected to a second directional connection 35 of a second base core 30 adjacent in the first direction. A first directional groove 34 is a part having a grooved shape toward the second direction on a first directional end of the yoke 31. A first directional groove 34 has an engaged shape after winding with a second directional protrusion 36 of a second base core 30 adjacent in the first direction.

[0047] A second directional connection 35 is a part formed on an outer circumference side of a second directional end of the yoke 31 to be connected to a first directional connection 33 of a second base core 30 adjacent in the second direction. A second directional protrusion 36 is a part formed by protruding from a second directional end of the yoke 31 in the second direction.

[0048] A second transition core 40 is a twelfth unit core T12of a second lamination L2, which is the unit core connected to a first unit core T1of the third lamination L3. As illustrated in (B) of Fig. 6, a second transition core 40 comprises a yoke 41, a tooth 42 formed to protrude to an inner circumference side of the circular lamination from the yoke 41, a first directional connection 43 formed on an outer circumference side of a first directional end of the yoke 41, a first directional groove 44 formed on a first direction end of the yoke 41, a second directional connection 45 formed on an outer circumference side of a second directional end of the yoke 41, and a second directional groove 46 formed on a second directional end of the yoke 41. A first directional connection 43 of the second transition core 40 is connected to a second directional connection 35 of a second base core 30, which is an eleventh unit core T11. A second directional connection 45 of a first transition core 20 is connected to a first directional connection 13 of a first base core 10, which is a first unit core T1of the third lamination L3.

[0049] The base material 100 has an odd numbered Nthlamination LNand an even numbered Nthlamination LNconnected alternately. The base material 100 is made of an electrical steel plate or a silicon steel plate. In the present invention, the bonding between two vertically adjacent laminations or the entire lamination is not achieved by conventional methods such as riveting, embossing or laser welding, but by curing of an adhesive or an adhesive layer coated on the surface of the electrical steel sheet.

[0050] An adhesive may be applied to the surface of the base material 100 while molding the base material 100 in a pressing device, with the winding process creating a bond between vertically adjacent laminations. Alternatively, a self-bonding (SB) electrical steel sheet having an adhesive layer coated on the surface of the electrical steel sheet may be used. In this case, after the winding process, the adhesive coating layer on the surface of the SB electrical steel sheet may be cured in a separate heating device to ensure complete bonding between laminations. In particular, the spiral motor core according to the present invention has a structure in which the bonding parts between adjacent unit cores have grooves and protrusions intersecting at each lamination of each layer, thereby achieving a firm bond between the laminations.

[0051] In the present invention, the Mthunit core TMof the first to M unit cores T1, T2, ..., TM-1, TMforming the first lamination L1is described as a first transition core 20, and the first to (M-1)thunit cores T1, T2, ..., TM-1are described as a first base core 10. However, it is also possible that the first unit core T1 is a second transition core 40, and the remaining second to Mthunit cores T2, T3, ..., TMare the first base core 10. In this case, the first unit core T1of the second lamination L2is the first transition core 20 and the second to Mthunit cores T2, T3, ..., TMare the second base core 30. As such, the same technical idea intended by the present invention may be achieved by changing the order of the first and second base cores 10, 30 and the first and second transition cores 20, 40.

[0052] 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 spiral motor core having a structure in which first to Nthlaminations L1, L2, ..., LNconnected to each other sequentially are wound and circularly laminated,wherein the first to Nthlaminations L1, L2, ..., LNdo not have embossing or holes formed, and the bonding between two adjacent laminations among the first to Nthlaminations L1, L2, ..., LNis achieved by curing of an adhesive or an adhesive coating layer (here, N is a natural number greater than or equal to 2).2.The spiral motor core of claim 1, wherein the first to Nthlaminations L1, L2, ..., LNare formed by molding a SB electrical steel sheet.3.The spiral motor core of claim 1, wherein each of the first to Nthlaminations L1, L2, ..., LNare formed by connecting first to Mthunit cores T1, T2, ..., TM-1, TM,wherein among the first to Nthlaminations L1, L2, ..., LN, the first to (M-1)thunit cores T1, T2, ..., TM-1of an odd numbered lamination L2k-1is a first base core 10, and the Mthunit core TMis a first transition core 20, andamong the first to Nthlaminations L1, L2, ..., LN, the first to (M-1)thunit cores T1, T2, ..., TM-1of an even numbered lamination L2kis a second base core 30, and the Mthunit core TMis a second transition core 40 (here, k is a natural number)4.The spiral motor core of claim 3, wherein the first base core 10, the first transition core 20, the second base core 30, and the second transition core 40 have yokes 11, 21, 31, 41, and teeth 12, 22, 32, 42 formed by protruding to inner or outer circumference sides of the yokes.5.The spiral motor core of claim 4, wherein the first base core 10 comprises a first directional connection 13 formed on an outer circumference side of a first directional end of the yoke 11, a first directional protrusion 14 formed on a first directional end of the yoke 11, a second directional connection 15 formed on an outer circumference side of a second directional end of the yoke 11, and a second directional groove 16 formed on a second directional end of the yoke 11.6.The spiral motor core of claim 4, wherein the first transition core 20 comprises a first directional connection 23 formed on an outer circumference side of a first directional end of the yoke 21, a first directional protrusion 24 formed on a first directional end of the yoke 21, a second directional connection 25 formed on an outer circumference side of a second directional end of the yoke 21, and a second directional protrusion 26 formed on a second directional end of the yoke 21.7.The spiral motor core of claim 4, wherein the second base core 30 comprises a first directional connection 33 formed on an outer circumference side of a first directional end of the yoke 31, a first directional groove 34 formed on a first directional end of the yoke 31, a second directional connection 35 formed on an outer circumference side of a second directional end of the yoke 31, and a second directional protrusion 36 formed on a second directional end of the yoke 31.8.The spiral motor core of claim 4, wherein the second transition core 40 comprises a first directional connection 43 formed on an outer circumference side of a first directional end of the yoke 41, a first directional groove 44 formed on a first directional end of the yoke 41, a second directional connection 45 formed on an outer circumference side of a second directional end of the yoke 41, and a second directional groove 46 formed on a second directional end of the yoke 41.

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