Stator, manufacturing method thereof, and vacuum cleaner including same

Abstract

The vacuum cleaner according to an embodiment of the present disclosure may include a cleaner body and a motor disposed inside the cleaner body. The motor may include a rotor and a stator including a stator core. The stator core may include: a plurality of yokes surrounding the rotor in a circumferential direction; a plurality of teeth corresponding to the plurality of yokes, respectively, wherein each of the plurality of teeth extends from a corresponding yoke among the plurality of yokes toward the rotor; and a plurality of electrical steel plates, wherein the plurality of electrical steel plates have yoke shapes corresponding to the plurality of yokes, respectively, and have tooth shapes corresponding to the plurality of teeth, respectively. The plurality of electrical steel plates may be stacked through an adhesive layer between two adjacent electrical steel plates among the plurality of electrical steel plates to form the stator core.

Description

Stator, method for manufacturing same, and vacuum cleaner including same

[0001] Various embodiments disclosed in this document relate to a stator, a method of manufacturing the same, and a vacuum cleaner including the same.

[0002] Recently, stick-type vacuum cleaners (or cordless vacuum cleaners) that omit certain components, such as the main body, hose, and power cord, have been attracting attention. Stick-type vacuum cleaners incorporate small fans to reduce weight and / or miniaturize the device. To generate high suction power, the small fans in stick-type vacuum cleaners require a drive motor (or mini fan motor) capable of high-speed rotation of over 50,000 rev / min, or even ultra-high-speed rotation of over 100,000 rev / min, with a certain torque.

[0003] A motor includes a rotor and a stator that interact electromagnetically. The rotor and / or stator utilize a core composed of a conductive metal material to generate the necessary magnetic field. The stator core (hereinafter referred to as the "stator core") used in stick vacuum cleaners is smaller than the stator cores used in motors in other home appliances. Due to the differences in manufacturing processes resulting from this smaller size, chain-shaped (or strip-shaped) stator cores are often used.

[0004] The stator core can be manufactured by laminating multiple thin electrical steel sheets. Typically, interlocking, a mechanical joint, is used to laminate multiple electrical steel sheets. Laminating using interlocking, however, can cause magnetic flux disturbances near the interlocking, potentially breaking down electrical insulation and increasing core loss in the stator core.

[0005] The above information may be provided as background art to aid in understanding the present disclosure. No claim or determination is made as to whether any of the above-described matters constitute prior art related to the present disclosure.

[0006] According to the present disclosure, a vacuum cleaner may include a cleaner body and a motor disposed inside the cleaner body. The motor may include a rotor and a stator including a stator core. The stator core may include a plurality of yokes circumferentially surrounding the rotor, a plurality of teeth each corresponding to the plurality of yokes, each of the plurality of teeth extending from a corresponding yoke among the plurality of yokes toward the rotor, and a plurality of electrical steel plates, each of the plurality of electrical steel plates having a yoke shape corresponding to each of the plurality of yokes and a tooth shape corresponding to each of the plurality of teeth. The plurality of electrical steel plates may be laminated between adjacent two of the plurality of electrical steel plates via an adhesive layer to form the stator core.

[0007] According to the present disclosure, a stator may include a stator core. The stator core may include a plurality of yokes circumferentially surrounding a center of the stator core, a plurality of teeth each corresponding to the plurality of yokes, each of the plurality of teeth extending from a corresponding yoke among the plurality of yokes to the center, and a plurality of electrical steel plates, each of the plurality of electrical steel plates having a yoke shape corresponding to each of the plurality of yokes and a tooth shape corresponding to each of the plurality of teeth. The plurality of electrical steel plates may be laminated with an adhesive layer between adjacent two electrical steel plates among the plurality of electrical steel plates to form the stator core.

[0008] According to the present disclosure, a method for manufacturing a stator including a plurality of yokes, each of which is connected to the other through a bending portion, a plurality of teeth corresponding to the plurality of yokes and each of which extends from a corresponding yoke among the plurality of yokes, and a plurality of electrical steel plates each having a yoke shape corresponding to each of the plurality of yokes and a tooth shape corresponding to each of the plurality of teeth, comprises: cutting a plurality of electrical steel plates to form the yoke shape and the tooth shape on each of the plurality of electrical steel plates; applying an adhesive to a surface of at least one of the cut electrical steel plates; stacking the plurality of cut electrical steel plates so that the adhesive layer is positioned between two adjacent electrical steel plates among the plurality of electrical steel plates to form an assembled stator; heating the assembled stator to harden the applied adhesive layer; injecting an insulating material onto at least a portion of each of the plurality of teeth of the assembled stator to form an insulator; winding a stator coil around the insulator; and bending the bending portion to form the stator core in an annular shape.

[0009] However, the problem to be solved in this disclosure is not limited to the problem mentioned above, and may be determined in various ways without departing from the spirit and scope of this disclosure.

[0010] FIG. 1 is a perspective view of a vacuum cleaner according to one embodiment of the present disclosure.

[0011] FIG. 2 is a perspective view of a suction motor according to one embodiment of the present disclosure.

[0012] FIG. 3 is an exploded perspective view of a suction motor according to one embodiment of the present disclosure.

[0013] Figure 4 is a cross-sectional view taken along line I-I' of Figure 2.

[0014] FIG. 5 is a perspective view of a stator core according to one embodiment of the present disclosure.

[0015] Fig. 6a is a plan view of the stator core before bending the stator core of Fig. 5.

[0016] Figure 6b is an enlarged view of part A of Figure 6a.

[0017] FIG. 7 is a drawing showing a state in which a plurality of electrical steel plates are laminated according to one embodiment of the present disclosure.

[0018] Fig. 8 is a cross-sectional view taken along line Ⅱ-Ⅱ' of Fig. 6a.

[0019] FIG. 9 is a perspective view of a stator core according to one embodiment of the present disclosure.

[0020] Fig. 10 is a plan view of the stator core before bending the stator core of Fig. 9.

[0021] FIG. 11 is a drawing showing a state in which a plurality of electrical steel plates are laminated according to one embodiment of the present disclosure.

[0022] Fig. 12 is a cross-sectional view taken along line Ⅲ-Ⅲ' of Fig. 10.

[0023] Figure 13 is a diagram showing iron loss according to the fastening method of the stator core and the number of embossments.

[0024] Figure 14 is a graph showing the height deviation of the stator core according to the method of fastening the stator core.

[0025] FIG. 15 is a manufacturing flowchart of a stator according to one embodiment of the present disclosure.

[0026] FIG. 16 is a drawing showing a stator core lamination process in a stator core manufacturing device according to one embodiment of the present disclosure.

[0027] FIG. 17 is a drawing showing a stator core lamination process in a stator core manufacturing device according to one embodiment of the present disclosure.

[0028] The following description refers to the attached drawings, and specific examples of implementations are illustrated within the drawings. Furthermore, other examples may be utilized and structural changes may be made without departing from the scope of the various examples.

[0029] It should be understood that the various embodiments and terms used in this document are not intended to limit the technical features described in this document to specific embodiments, but rather to encompass various modifications, equivalents, or alternatives of the embodiments.

[0030] The singular form of a noun corresponding to an item may include one or more items, unless the context clearly indicates otherwise.

[0031] In this document, each of the phrases "A or B", "at least one of A and B", "at least one of A or B", "A, B, or C", "at least one of A, B, and C", and "at least one of A, B, or C" may include any one of the items listed together in that phrase, or all possible combinations thereof.

[0032] Terms such as "first," "second," or "first" or "second" may be used simply to distinguish one component from another and do not qualify the components in any other respect (e.g., importance or order).

[0033] When a component (e.g., a first component) is referred to as being “coupled” or “connected” to another component (e.g., a second component), with or without the terms “functionally” or “communicatively,” it means that the component can be connected to the other component directly (e.g., wired), wirelessly, or through a third component.

[0034] The terms “include” or “have” are intended to specify the presence of a feature, number, step, operation, component, part or combination thereof described in this document, but do not preclude the presence or addition of one or more other features, numbers, steps, operations, components, parts or combinations thereof.

[0035] When a component is said to be “connected,” “coupled,” “supported,” or “in contact with” another component, this includes not only cases where the components are directly connected, coupled, supported, or in contact, but also cases where the components are indirectly connected, coupled, supported, or in contact through a third component.

[0036] When we say that a component is "on" another component, this includes not only cases where the component is in contact with the other component, but also cases where there is another component between the two components.

[0037] The term “and / or” includes any combination of a plurality of related described elements or any one of a plurality of related described elements.

[0038] The operating principle and embodiments of the present invention will be described with reference to the attached drawings below.

[0039] FIG. 1 is a perspective view of a vacuum cleaner according to one embodiment of the present disclosure.

[0040] Referring to FIG. 1, a vacuum cleaner (1) may include at least one of a cleaner body (10), a suction head (20), a stick (30), a dust collector (40), or a suction motor (100).

[0041] The suction motor (100) can be applied to various home appliances in addition to the vacuum cleaner (1). Hereinafter, the description will focus on a stick-type vacuum cleaner (1) including the suction motor (100).

[0042] According to one embodiment, the vacuum cleaner body (10) can accommodate a battery (11). The battery (11) can supply power to the suction motor (100).

[0043] According to one embodiment, the vacuum cleaner body (10) may be provided with a handle (13) that can be held by a user. The handle (13) is a part that is connected to the vacuum cleaner body (10) and may be provided so that a user can hold it and operate the vacuum cleaner (1). For example, the handle (13) may be provided with an operating portion (not shown), and the user can operate the vacuum cleaner (1) using the operating portion.

[0044] According to one embodiment, the suction head (20) can be connected to the cleaner body (10) via a stick (30). The suction head (20) is provided at the lower portion of the cleaner body (10) and can come into contact with the surface to be cleaned. When the suction head (20) is in contact with the surface to be cleaned, the suction force generated from the suction motor (100) can cause foreign substances such as dust or dirt on the surface to be cleaned to be drawn into the interior of the cleaner body (10) (e.g., dust collector (40)).

[0045] According to one embodiment, the stick (30) may have a hollow cylindrical shape. The stick (30) may serve as a passage that guides foreign substances sucked by the suction head (20) to the cleaner body (10).

[0046] According to one embodiment, the dust collector (40) may be provided to store foreign substances such as dust or dirt on the surface to be cleaned that are sucked in from the suction head (50). The dust collector (30) may be detachably connected to the suction motor (100) to discharge the stored foreign substances to the outside.

[0047] According to one embodiment, the suction motor (100) can create an air flow from the suction head (20) toward the inside of the cleaner body (10). The suction motor (100) can include a motor (e.g., the motor (M) of FIG. 3) for driving the vacuum cleaner (1). The motor (M) can generate power to generate a suction force inside the cleaner body (10).

[0048] FIG. 2 is a perspective view of a suction motor according to one embodiment of the present disclosure.

[0049] FIG. 3 is an exploded perspective view of a suction motor according to one embodiment of the present disclosure.

[0050] Figure 4 is a cross-sectional view taken along line I-I' of Figure 2.

[0051] Referring to FIGS. 2 to 4, the suction motor (100) may include at least one of a housing (110), an impeller (120), a motor frame (130), a motor (M), or a rotating shaft (160).

[0052] According to one embodiment, the housing (110) may have a separable multi-stage structure. The housing (110) may include a first housing (111), a second housing (112) configured to be coupled with the first housing (111), and a third housing (113) configured to be coupled with the second housing (112).

[0053] According to one embodiment, the housing (110) may form an internal space in which components such as an impeller (120), a motor frame (130), or a motor (M) may be placed.

[0054] According to one embodiment, the housing (1210) may have a cylindrical shape.

[0055] According to one embodiment, the first housing (111) and the second housing (112) may be provided to be separable in the axial direction of the rotating shaft (160).

[0056] According to one embodiment, the second housing (112) and the third housing (113) may be provided to be separable in the axial direction of the rotating shaft (160).

[0057] According to one embodiment, an intake port (111a) may be provided on the upper part of the first housing (111) to introduce air into the interior of the housing (110) when the motor (M) is driven.

[0058] According to one embodiment, an exhaust port (113a) may be provided at the lower portion of the third housing (113) to exhaust air to the outside of the housing (110).

[0059] According to one embodiment, the first housing (111), the second housing (112) and the third housing may be coupled to each other to form an air path leading from the intake port (111a) to the exhaust port (113a).

[0060] In one embodiment, the impeller (120) may include a shaft coupling portion (121), a hub (122), or a plurality of blades (123). In one embodiment, the impeller (120) may be positioned inside the suction port (111a) of the first housing (111).

[0061] In one embodiment, the impeller (120) may be coupled to a portion of a rotating shaft (160) by a shaft coupling portion (121). The impeller (120) may rotate together with the rotor (150) by the coupling of the shaft coupling portion (121) and the rotating shaft (160), thereby forming an air flow. The shaft coupling portion (121) may be located at the top of the hub (122).

[0062] According to one embodiment, the hub (122) can guide air introduced through the intake port (111a). The hub (122) can be designed such that its radius increases as it moves away from the intake port (111a) along the axial direction of the rotating shaft (160). The hub (122) can be designed such that air introduced along the axial direction of the rotating shaft (160) is discharged in the radial direction of the rotating shaft (160). The hub (122) can extend from the outer surface of the shaft coupling member (121) such that the shaft coupling member (121) is positioned at the center.

[0063] According to one embodiment, a plurality of blades (123) may protrude from the outer surface (or upper surface) of the hub (122). The plurality of blades (123) may be arranged to form an airflow by rotating together with the hub (122). The plurality of blades (123) may be provided integrally with the hub (122).

[0064] According to one embodiment, the motor frame (130) can stably fix the motor (M) within the housing (110). According to one embodiment, the motor frame (130) can include an upper motor frame (131) and a lower motor frame (132).

[0065] According to one embodiment, the upper motor frame (131) and the lower motor frame (132) can be coupled to each other with the stator (140) and the rotor (150) therebetween. For example, the stator (140) and the rotor (150) can be positioned inside the motor frames (131, 132) that are coupled to each other. The upper motor frame (131) and the lower motor frame (132) can be coupled by a plurality of coupling members (P). For example, the coupling members (P) can be screws. The motor frame (130) (e.g., the upper motor frame (131)) can be positioned below the impeller (120). The motor frame (130) (e.g., the upper motor frame (131)) can be positioned such that an outer surface thereof is adjacent to an inner surface of the diffuser (133). For example, the diffuser (133) may be located between the second housing (112) and the motor frame (130).

[0066] According to one embodiment, the diffuser (133) may be positioned within the housing (110) (e.g., the second housing (112)). The diffuser (133) may be provided in a cylindrical shape, for example, along the inner surface of the housing (110) (e.g., the second housing (112)). The diffuser (133) may be formed with a plurality of ribs. The diffuser (133) may be provided to increase the pressure of the air while guiding the air discharged by the impeller (120).

[0067] According to one embodiment, the motor (M) may include a stator (hereinafter, stator) (140) and a rotor (hereinafter, rotor) (150). The motor (M) may be provided in the internal space of the housing (110).

[0068] According to one embodiment, the stator (140) may include a stator core (141), an insulator (143), or a stator coil (145).

[0069] According to one embodiment, the stator (140) may be configured to generate magnetic flux when current is applied to the stator coil (145). The stator core (141) may have a cylindrical shape. A rotor receiving portion (e.g., rotor receiving portion (201) of FIG. 5) for receiving a rotor (150) may be provided at the center of the stator core (141).

[0070] According to one embodiment, the insulator (143) may be formed of a material having electrical insulation properties. The insulator (143) may surround at least a portion of the stator core (141) to insulate the stator core (141) and the stator coil (145). For example, the insulator (143) may include an upper insulator (143a) that surrounds the upper portion of the stator core (141) and a lower insulator (143b) that surrounds the lower portion of the stator core (141). The insulator (143) may be injection molded.

[0071] According to one embodiment, the stator coil (145) may be wound (or wrapped) around the stator core (141) while the insulator (143) is coupled to the stator core (141).

[0072] According to one embodiment, the rotor (150) may be provided as a permanent magnet having magnetic properties or may include a coil having electromagnetic properties. The rotor (150) may be inserted into the rotor receiving portion (201) of the stator core (141). The rotor (150) may be provided to be rotatable by electromagnetic interaction with the stator (140). In one embodiment of the present invention, it is assumed that the rotor (150) is provided as a permanent magnet.

[0073] According to one embodiment, the rotary shaft (160) may be arranged to penetrate the rotor (150). An impeller (120) may be coupled to one end of the rotary shaft (160) adjacent to the suction port (111a). Accordingly, the rotary shaft (160) may transmit the rotational force of the rotor (150) to the impeller (120).

[0074] According to one embodiment, a first bearing (171) and a second bearing (172) may be arranged on the rotary shaft (160) to support the rotation of the rotary shaft (160). The first bearing (171) may be arranged, for example, to surround the outer surface of the rotary shaft (160) at the upper portion of the motor frame (130). The second bearing (172) may be arranged, for example, to surround the outer surface of the rotary shaft (160) at the lower portion of the motor frames (131, 132).

[0075] FIG. 5 is a perspective view of a stator core according to one embodiment of the present disclosure.

[0076] The embodiment of FIG. 5 can be optionally combined with the embodiments of FIGS. 1 to 4 and FIGS. 6a to 8.

[0077] The configuration of the stator core (200) of FIG. 5 may be all or part of the same as the configuration of the stator core (141) of FIGS. 3 and 4.

[0078] Referring to FIG. 5, a stator core (200) according to one embodiment may have a cylindrical shape. For example, the stator core (200) may be manufactured by bending a plurality of segmented cores (200a) (see FIG. 6a) that are connected to each other and have a band (or chain) shape. The stator core (200) may be manufactured by stacking a plurality of thin electrical steel plates (or core sheets, electrical plates) (e.g., electrical steel plates (200b) of FIG. 7). A method for manufacturing the stator core (200) will be described later with reference to FIGS. 15 to 17.

[0079] According to one embodiment, the stator core (200) may be provided with a hollow rotor receiving portion (201) in the center into which a rotor (e.g., rotor (160) of FIG. 3) is inserted.

[0080] According to one embodiment, the stator core (200) may include a plurality of split cores (200a). Each split core (200a) may include one yoke (210) and one tooth (220). For example, the stator core (200) may be composed of six split cores (200a) as illustrated in FIG. 5. However, the present disclosure is not limited thereto. Hereinafter, for convenience of explanation, it is assumed that the stator core (200) is composed of six split cores (200a).

[0081] According to one embodiment, the yoke (210) may have an arc shape. For example, the outer surface (210a) of the yoke (210) may have a curved surface. The width of the yoke (210) may be designed to be, for example, 1 to 3 mm. When the stator core (200) is viewed from above, the stator core (200) may have a circular shape due to a plurality of yokes (210) that are connected to each other. The plurality of yokes (210) may define an outer diameter of the stator core (200). The outer diameter of the stator core (200) (or the outer diameter of the yoke (210)) may be designed to be, for example, 20 to 40 mm.

[0082] According to one embodiment, the teeth (220) may extend radially inwardly from the yoke (210) (e.g., in the direction toward the rotor receiving portion (210). The width of the teeth (220) may be designed to be, for example, 0.5 to 3 mm. The teeth (220) may be a portion of a stator core (200) on which a stator coil (e.g., a stator coil (145) of FIG. 3) is wound. A plurality of teeth (220) may be spaced at substantially equal intervals along the circumferential direction of the stator core (200). A slot (203), which is an empty space, may be formed between two adjacent teeth (220) among the plurality of teeth (220). The slot (203) may be defined by an inner surface of the yoke (210) and the facing inner surfaces of two adjacent teeth (220). A stator coil (145) wound on a tooth (220) can be positioned in the slot (203).

[0083] According to one embodiment, a tooth ear (230) protruding on both sides may be provided at the tip (or free end) of the tooth (220). The tip surface (221) of the tooth (220) may be enlarged in area as the tooth ear (230) is formed. When the stator core (200) is viewed from above, the plurality of tooth ears (230) may form a circular shape. The plurality of tooth ears (230) may define an inner diameter of the stator core (200). The inner diameter of the stator core (200) (or the inner diameter of the tooth (220)) may be, for example, 5 to 20 mm. The plurality of tooth ears (230) may form a rotor receiving portion (201) radially inward.

[0084] Fig. 6a is a plan view of the stator core before bending the stator core of Fig. 5.

[0085] Figure 6b is an enlarged view of part A of Figure 6a.

[0086] The embodiments of FIGS. 6A and 6B can be optionally combined with the embodiments of FIGS. 1 to 5 and FIGS. 7 and 8.

[0087] The configuration of the stator core (200') of FIGS. 6a and 6b may be all or part of the same as the configuration of the stator core (200) of FIG. 5.

[0088] Referring to FIGS. 6a and 6b, a stator core (200') according to one embodiment may include a plurality of split cores (200a) having one yoke (210) and teeth (220).

[0089] According to one embodiment, a plurality of split cores (200a-1, 200a-2, 200a-3, 200a-4, 200a-5, 200a-6) can be connected to each other through a bending portion (240) provided at one end of an outer surface (210a) of an adjacent yoke (210). For example, a plurality of split cores (200a-1, 200a-2, 200a-3, 200a-4, 200a-5, 200a-6) can be connected to each other in a horizontal direction. In this case, the stator core (200') can have a belt (or chain) shape. The belt-shaped stator core (200') can be bent inward based on the bending portion (240) to be transformed into a ring-shaped stator core (200) as illustrated in FIG. 5.

[0090] According to one embodiment, the bending portion (240) may include a connecting portion (241), a notch portion (242), or a bending space (243). The bending portion (240) may be a portion that is bent when the belt-shaped stator core (200') is transformed into a ring-shaped stator core (200). The bending portion (240) may be provided between the yokes (210) of neighboring split cores (200a-1, 200a-2, 200a-3, 200a-4, 200a-5, 200a-6).

[0091] According to one embodiment, the connecting portion (241) can connect the side surfaces (211, 212) of the yokes (210) of the neighboring split cores (200a-1, 200a-2, 200a-3, 200a-4, 200a-5, 200a-6) to each other. The connecting portion (241) can be positioned radially outward on the side surfaces (212, 212) of the yokes (210). For example, the connecting portion (241) can be positioned closer to the outer surface (210a) of the yoke (210) than to the inner surface of the yoke (210). The thickness of the connecting portion (241) can be provided to be thinner than the thickness of the yoke (210). For example, the connecting portion (241) can be provided as a thin-walled portion to facilitate bending.

[0092] According to one embodiment, the notch portion (242) may be a space formed between the yokes (210) of neighboring split cores (200a-1, 200a-2, 200a-3, 200a-4, 200a-5, 200a-6). The notch portion (242) may be a cut portion in an electrical steel plate forming a band-shaped stator core (200') except for a connecting portion (241). The notch portion (242) may be opened radially inward. The notch portion (242) may have a U- or V-shape. The notch portion (242) may guide bending of the band-shaped stator core (200'). For example, a belt-shaped stator core (200') can be bent so that the side surfaces (211, 212) of the yokes (210) of neighboring split cores (200a-1, 200a-2, 200a-3, 200a-4, 200a-5, 200a-6) come closer to each other based on the notch portion (242).

[0093] According to one embodiment, the recessed portion (243) may be formed by being recessed from the inner surface of the connecting portion (241). The recessed portion (243) may be a space provided between the connecting portion (241) and the notch portion (242). When the belt-shaped stator core (200') is transformed into the ring-shaped stator core (200), the recessed portion (243) may be closed by the yokes (210) of the neighboring split cores (200a-1, 200a-2, 200a-3, 200a-4, 200a-5, 200a-6) coming into contact with each other, thereby closing the portion opened toward the notch portion (242).

[0094] FIG. 7 is a drawing showing a state in which a plurality of electrical steel plates are laminated according to one embodiment of the present disclosure.

[0095] Fig. 8 is a cross-sectional view taken along line Ⅱ-Ⅱ' of Fig. 6a.

[0096] The embodiments of FIGS. 7 and 8 can be optionally combined with the embodiments of FIGS. 1 to 6.

[0097] Referring to FIGS. 7 and 8, a belt-shaped stator core (200') according to one embodiment can be manufactured by stacking a plurality of electrical steel plates (200b) that are thin plates to form one stator core (200').

[0098] According to one embodiment, the electrical steel plate (200b) can be press-processed into a shape corresponding to a plurality of yokes (210) connected through a bending portion (240) to have a band shape and a plurality of teeth (220) extending from each yoke (210).

[0099] According to one embodiment, a plurality of electrical steel plates (200b-1, 200b-2, ..., 200b-n) may be bonded to each other by an adhesive layer (250). For example, a plurality of electrical steel plates (200b-1, 200b-2, 200b-3, 200b-4, 200b-5) may be stacked in a vertical direction (e.g., up-down direction). An adhesive layer (250) may be disposed between the stacked plurality of electrical steel plates (200b-1, 200b-2, 200b-3, 200b-4, 200b-5).

[0100] According to one embodiment, the adhesive layer (250) may be composed of a thermosetting adhesive. For example, the adhesive layer (250) may include at least one of an epoxy resin, a polyester resin, and an acrylic resin. The stator core (200') may be manufactured by stacking a plurality of electrical steel plates (200b-1, 200b-2, 200b-3, 200b-4, 200b-5), and then heating the stacked plurality of electrical steel plates (200b-1, 200b-2, 200b-3, 200b-4, 200b-5) to a predetermined temperature (e.g., 100°C) or higher to harden the adhesive layer (250).

[0101] FIG. 9 is a perspective view of a stator core according to one embodiment of the present disclosure.

[0102] Fig. 10 is a plan view of the stator core before bending the stator core of Fig. 9.

[0103] FIG. 11 is a drawing showing a state in which a plurality of electrical steel plates are laminated according to one embodiment of the present disclosure.

[0104] Fig. 12 is a cross-sectional view taken along line Ⅲ-Ⅲ' of Fig. 10.

[0105] The embodiments of FIGS. 9 to 12 can be optionally combined with the embodiments of FIGS. 1 to 4.

[0106] The configuration of the stator core (200-1, 200-1') of FIGS. 9 to 12 may be all or part of the same as the configuration of the stator core (141) of FIGS. 3 and 4.

[0107] The configuration of the stator core (200-1, 200-1') of FIGS. 9 to 12 may be all or part of the same as the configuration of the stator core (200, 200') of FIGS. 5 to 8.

[0108] Referring to FIGS. 9 to 12, a stator core (200-1) according to one embodiment can be manufactured by bending a bending portion (240) so that a plurality of split cores (200c) connected to each other to have a belt (or chain) shape form a cylindrical shape. The stator core (200-1) can be manufactured by stacking a plurality of thin electrical steel plates (or core sheets) (200d).

[0109] According to one embodiment, the stator core (200-1) may include a plurality of split cores (200c) having one yoke (210) and one tooth (220). For example, the stator core (200-1) may be composed of six split cores (200a) as illustrated in FIG. 9. However, the present disclosure is not limited thereto. Hereinafter, for convenience of explanation, it is assumed that the stator core (200-1) is composed of six split cores (200c).

[0110] According to one embodiment, a plurality of split cores (200c-1, 200c-2, 200c-3, 200c-4, 200c-5, 200c-6) can be connected to each other through a bending portion (240) provided at one end of an adjacent tooth (220). The stator core (200-1') can have a belt (or chain) shape. The belt-shaped stator core (200-1') can be bent inward based on the bending portion (240) to be transformed into a ring-shaped stator core (200-1).

[0111] According to one embodiment, a belt-shaped stator core (200-1') can be manufactured by stacking a plurality of thin electrical steel plates (200d-1, 200d-2, ..., 200d-n) to form one stator core (200-1').

[0112] According to one embodiment, the electrical steel plate (200d) can be press-processed (or punched) into a shape corresponding to a plurality of yokes (210) connected through a bending portion (240) to have a band shape and a plurality of teeth (220) extending from each yoke (210).

[0113] According to one embodiment, an electrical steel plate (200d) may be provided with an interlocking portion (260) for laminating a plurality of electrical steel plates (200d). The interlocking portion (260) may be formed by press working. The plurality of electrical steel plates (200d) may be stably laminated by having the interlocking portions (260) contact each other during lamination.

[0114] According to one embodiment, the interlocking portion (260) may have an embossing structure. The interlocking portion (260) may include a protrusion (261) from a first surface (200da) of the electrical steel plate (200d) and a recess (262) from a second surface (200db) of the electrical steel plate (200d) opposite to the first surface (200da). For example, the interlocking portion (260) may have a shape that is recessed from the upper surface of the electrical steel plate (200d) and protrudes from the lower surface. For example, the interlocking portion (260) may have a vertical cross-section in a U- or V-shape. The interlocking portion (260) may be called an emboss.

[0115] According to one embodiment, the number of interlocking portions (260) may be smaller than the total number of yokes (210) and teeth (220) included in the electrical steel plates (200d). For example, when a plurality of electrical steel plates (200d) are laminated, at least two interlocking portions (260) may be provided for each electrical steel plate (200d) to prevent separation of the laminated electrical steel plates (200d). Specifically, as illustrated in FIG. 10, when the stator core (200-1') is composed of six split cores (200c-1, 200c-2, 200c-3, 200c-4, 200c-5, 200c-6), the number of interlocking portions (260) may be smaller than 12, which is the total number of yokes (210) and teeth (220).

[0116] According to one embodiment, the interlocking portion (260) may be divided and arranged on the yokes (210) and teeth (220) of the plurality of split cores (200c). For example, the interlocking portion (260) may be arranged to form a pair on the yokes (210) and teeth (220) of one split core (200c) among the plurality of split cores (200c). For example, the interlocking portion (260) may be divided and arranged on the yokes (210) and teeth (220) of different split cores (200c) among the plurality of split cores (200c). For example, the interlocking portion (260) may be divided and arranged on the yokes (210) of different split cores (200c) among the plurality of split cores (200c). For example, the interlocking portion (260) may be divided and placed on the teeth (220) of different split cores (200c) among the plurality of split cores (200c).

[0117] According to one embodiment, a plurality of electrical steel plates (200d-1, 200d-2, ..., 200d-n) can be bonded to each other by an adhesive layer (250). For example, a plurality of electrical steel plates (200d-1, 200d-2, 200d-3, 200d-4, 200d-5) can be stacked in a vertical direction (e.g., up-down direction). An adhesive layer (250) can be disposed between the stacked plurality of electrical steel plates (200b-1, 200b-2, 200b-3, 200b-4, 200b-5). The stator core (200-1') can be manufactured by stacking a plurality of electrical steel plates (200d-1, 200d-2, 200b-3, 200d-4, 200d-5), and then heating the stacked plurality of electrical steel plates (200d-1, 200d-2, 200d-3, 200d-4, 200d-5) to a predetermined temperature (e.g., 100°C) or higher to harden the adhesive layer (250).

[0118] Figure 13 is a drawing showing the change in iron loss according to the fastening method of the stator core and the number of interlocking parts.

[0119] Referring to Fig. 13, a stator core in the shape of a belt formed by laminating a plurality of electrical steel plates may have a change in iron loss (wattage loss, or core loss) depending on the method of fastening (or laminating) the plurality of electrical steel plates and the number of interlocking portions (or embossing) (250) formed on the electrical steel plates.

[0120] For example, Fig. 13 shows the iron loss measured by varying the maximum magnetic flux density (T, Tesla) and frequency (Hz) and the fastening method of multiple electrical steel plates (e.g., fastening method using an adhesive layer (250) or fastening method using an interlocking portion (260)) based on the number of split cores being 6 and the total number of yokes and teeth being 12.

[0121] Although not specifically stated, when 12 interlocking portions (260) are provided on multiple electrical steel plates and the adhesive layer (250) is not mixed, it can be confirmed that the iron loss is 3.58 W at W 15 / 50, 8.75 W / kg at W 10 / 200, 20.55 W / kg at W 10 / 400, and 52.34 W / kg at W 10 / 800.

[0122] As shown in Fig. 12, when four interlocking portions (260) are provided on multiple electrical steel plates and the adhesive layer (250) is mixed, it can be confirmed that the iron loss is 3.38 W / kg at W 15 / 50, 8.25 W / kg at W 10 / 200, 19.44 W / kg at W 10 / 400, and 49.89 W / kg at W 10 / 800.

[0123] Although not specifically stated, when two interlocking portions (260) are provided on multiple electrical steel plates and the adhesive layer (250) is mixed, it can be confirmed that the iron loss is 3.33 W / kg at W 15 / 50, 8.17 W / kg at W 10 / 200, 19.35 W / kg at W 10 / 400, and 49.60 W / kg at W 10 / 800.

[0124] As shown in Fig. 8, when the interlocking portion (260) is not provided on the plurality of electrical steel plates and only the adhesive layer (250) is used, it can be confirmed that the iron loss is 2.89 W at W 15 / 50, 7.50 W at W 10 / 200, 17.90 W at W 10 / 400, and 46.82 W at W 10 / 800.

[0125] As a result, it can be confirmed that as the number of interlocking parts (260) decreases, the iron loss occurring in the stator core decreases.

[0126] Figure 14 is a graph showing the height deviation of the stator core according to the method of fastening the stator core.

[0127] Fig. 14 shows the height deviation in a stator core having a lower height specification limit of 20.75 mm and an upper height specification limit of 21.25 mm when a plurality of electrical steel plates are laminated through an interlocking portion (260) (Fig. 14 (a)) and when a plurality of regular steel plates are laminated through an adhesive layer (250) (Fig. 14 (b)).

[0128] Referring to (a) of Fig. 14, when a plurality of electrical steel plates are laminated through an interlocking portion (260) without using an adhesive layer (250), it can be confirmed that the average height of the stator core is 20.84 mm and the standard deviation is 0.036.

[0129] Referring to (b) of Fig. 14, when a plurality of electrical steel plates are laminated through an adhesive layer (250) without using an interlocking portion (260), it can be confirmed that the average height of the stator core is 20.94 mm and the standard deviation is 0.018.

[0130] As a result, it can be confirmed that the method using the adhesive layer (250) has a smaller height deviation than the method using the interlocking portion (260) in the method of fastening multiple electrical steel plates.

[0131] FIG. 15 is a manufacturing flowchart of a stator according to one embodiment of the present disclosure.

[0132] FIG. 16 is a drawing showing a stator core lamination process in a stator core manufacturing device according to one embodiment of the present disclosure.

[0133] FIG. 17 is a drawing showing a stator core lamination process in a stator core manufacturing device according to one embodiment of the present disclosure.

[0134] Referring to FIGS. 15 to 17, a method for manufacturing a stator core (200, 200-1) according to one embodiment may include a step (1510) of pressing (or punching) an electrical steel plate (200b) in a band shape, the band shape of which corresponds to a split core (200a) and is connected to each other. For example, an electrical steel plate (200b) unwound from a coil (not shown) and sent out along an arrow direction (F) may have a shape corresponding to a yoke (210) and a tooth (220) of the stator core (200, 200-1) by being punched by a mold device (not shown) disposed in a manufacturing device (300).

[0135] According to one embodiment, a method for manufacturing a stator core (200, 200-1) may include a step (1520) of applying an adhesive (G) to the lower surface of a press-formed electrical steel plate (200b). For example, the adhesive (G) may be applied to the lower surface of the electrical steel plate (200b) in a dot pattern via an injector (310).

[0136] According to one embodiment, a method for manufacturing a stator core (200, 200-1) may include a step (1530) of sequentially stacking a plurality of electrical steel plates (200b) to which an adhesive (G) is applied. For example, when stacking a plurality of electrical steel plates (200b) using only an adhesive (G), as illustrated in FIG. 16, a block-shaped male mold (320) may be lowered toward a female mold (330) on which an electrical steel plate (200b) is placed, and the plurality of electrical steel plates (200b) may be stacked by contacting and pressing the electrical steel plates (200b). For example, when using an adhesive (G) and an interlocking portion (260) together, as illustrated in Fig. 17, a male mold (320a) having a protrusion (321) in a protruding shape is lowered toward a female mold (330) on which an electrical steel plate (200b) is placed, and a plurality of electrical steel plates (200b) can be laminated by contacting and pressing the electrical steel plates (200b). At this time, as the electrical steel plates (200b) are pressed by the protrusion (321) of the male mold (320a), an interlocking portion (260) can be formed on the electrical steel plates (200d).

[0137] According to one embodiment, the method for manufacturing a stator core (200, 200-1) may include a heating process (1540) for heating a plurality of laminated electrical steel plates (200b, 200d). For example, the plurality of laminated electrical steel plates (200b, 200d) may be heated simultaneously with process 1530 by a heater (not shown) provided within the male and female molds (320, 330), thereby hardening the applied adhesive (G). For example, the plurality of laminated electrical steel plates (200b, 200d) may be heated after process 1530 by a separate heater (not shown) provided outside the male and female molds (320, 330), thereby hardening the applied adhesive (G).

[0138] According to one embodiment, a method for manufacturing a stator core (200, 200-1) may include a process (1550) of injection molding an insulator (143) surrounding a tooth (220) of a belt-shaped stator core (200', 200-1').

[0139] According to one embodiment, a method for manufacturing a stator core (200, 200-1) may include a process (1560) of winding a stator coil (145) on an injection-molded insulator (143) and / or teeth (220).

[0140] In one embodiment, a method for manufacturing a stator core (200, 200-1) may include a step (1570) of bending and / or welding a strip-shaped stator core (200', 200-1') around which a stator coil (145) is wound, based on a bending portion (240). For example, the strip-shaped stator core (200', 200-1') may be bent inwardly based on the bending portion (240) to be transformed into an annular stator core (200, 200-1). Thereafter, the annular stator core (200, 200-1) may be integrated by welding the joint of the bending portion (240).

[0141] A vacuum cleaner (1) according to one embodiment of the present disclosure may include a cleaner body (10) and a motor (M) disposed inside the cleaner body (10). The motor (M) may include a rotor (150) and a stator (140) including a stator core (200, 200-1). The above stator core (200, 200-1) may include a plurality of yokes (210) circumferentially surrounding the rotor (210), a plurality of teeth (220) each corresponding to the plurality of yokes (210), each of the teeth (220) extending from a corresponding yoke (210) among the plurality of yokes (210) toward the rotor (150), and a plurality of electrical steel plates (200b, 200d), each of the steel plates of the plurality of electrical steel plates (200b, 200d) having a yoke shape corresponding to each of the plurality of yokes (210) and a tooth shape corresponding to each of the plurality of teeth (220). The above plurality of electrical steel plates (200b, 200d) can be laminated through an adhesive layer (250) between two adjacent electrical steel plates among the above plurality of electrical steel plates (200b, 200d) to form the stator core (200, 200-1).

[0142] According to one embodiment, each of the plurality of electrical steel plates (200d) may include an interlocking portion (260) having an embossing structure for laminating the plurality of electrical steel plates (200d) such that, in the laminate of the plurality of electrical steel plates (200d), the interlocking portions (260) of adjacent electrical steel plates among the plurality of electrical steel plates (200d) are interlocked.

[0143] According to one embodiment, the interlocking portion (260) may include a protrusion (261) from a first surface (200da) and a recess (262) from a second surface (200db) opposite to the first surface. The protrusion (261) may protrude into a recess (262) of an adjacent electrical steel plate among the plurality of electrical steel plates (200d) in the laminate of the plurality of electrical steel plates (200d).

[0144] According to one embodiment, the interlocking portion (260) may be arranged in at least one of at least one yoke shape or at least one tooth shape.

[0145] According to one embodiment, for each electrical steel plate among the plurality of electrical steel plates (200d), the number of the interlocking portions (260) may be less than the sum of the number of the yoke shapes and the number of the tooth shapes.

[0146] According to one embodiment, the interlocking portion (260) may include two or more interlocking portions (260).

[0147] According to one embodiment, the stator core (200, 200-1) may include a bending portion (240) that connects adjacent yokes (210) among the plurality of yokes (210). The bending portion (240) may be bent toward the center of the stator core (200, 200-1) so that the stator core (200, 200-1) has a ring shape.

[0148] According to one embodiment, the adhesive layer (250) may include a thermosetting adhesive.

[0149] According to one embodiment, the width of each yoke (210) among the plurality of yokes (210) may be 1 to 3 mm. The width of each tooth (220) among the plurality of teeth (220) may be 0.5 to 3 mm.

[0150] According to one embodiment, the stator core (200, 200-1) may have a ring shape. The outer diameter of each yoke (210) among the plurality of yokes (210) may be 20 to 40 mm.

[0151] According to one embodiment, the stator core (200, 200-1) may have a ring shape. The inner diameter of each tooth (220) among the plurality of teeth (220) may be 5 to 20 mm.

[0152] A stator (140) according to one embodiment of the present disclosure may include a stator core (200, 200-1). The above stator core (200, 200-1) may include a plurality of yokes (210) circumferentially surrounding the center of the stator core (200, 200-1), a plurality of teeth (220) each corresponding to the plurality of yokes (210), each of the teeth (220) extending from a corresponding yoke (210) among the plurality of yokes (210) toward the center, and a plurality of electrical steel plates (200b, 200d), each of the electrical steel plates (200b, 200d) having a yoke shape corresponding to each of the plurality of yokes (210) and a tooth shape corresponding to each of the plurality of teeth (220). The above plurality of electrical steel plates (200b, 200d) can be laminated through an adhesive layer (250) between two adjacent electrical steel plates among the above plurality of electrical steel plates (200b, 200d) to form the stator core (200, 200-1).

[0153] According to one embodiment of the present disclosure, a method for manufacturing a stator (140) including a plurality of yokes (210) connected to each other through a bending portion (240), a plurality of teeth (220) corresponding to the plurality of yokes (210) and each extending from a corresponding yoke among the plurality of yokes (210), and a plurality of electrical steel plates (200b, 200d) each having a yoke shape corresponding to each of the plurality of yokes (210) and a tooth shape corresponding to each of the plurality of teeth (220), comprises: cutting a plurality of electrical steel plates to form the yoke shape and the tooth shape on each of the plurality of electrical steel plates (200b, 200d), applying an adhesive (G) to a surface of at least one of the cut electrical steel plates (200b, 200d), and stacking the plurality of cut electrical steel plates (200b, 200d) so that the adhesive layer (G) is formed on the plurality of electrical steel plates. A stator (200', 200-1') is formed by positioning the assembled stator between two adjacent electrical steel plates (200b, 200d), the assembled stator (200', 200-1') is heated to harden the applied adhesive layer (G), an insulating material is injected into at least a portion of each tooth among a plurality of teeth (220) of the assembled stator (200', 200-1') to form an insulator (143), a stator coil (145) is wound around the insulator (143), and the bending portion (240) is bent to form the stator core (200', 200-1') in a ring shape.

[0154] According to one embodiment, a method for manufacturing a stator (140) includes embossing an interlocking portion (260) onto each electrical steel plate among the plurality of electrical steel plates (200b), so that the interlocking portions (260) of adjacent electrical steel plates among the plurality of electrical steel plates (200b) can be interlocked when stacked.

[0155] In one embodiment, the heating may be performed simultaneously with the lamination or after the lamination is completed.

Claims

1. In the vacuum cleaner (1), Vacuum cleaner body (10); and Includes a motor (M) placed inside the above vacuum cleaner body (10), The above motor (M) is, Rotor (150); and A stator (140) including a stator core (200, 200-1) is included, The above stator core (200, 200-1) is A plurality of yokes (210) surrounding the rotor (210) in a circumferential direction; A plurality of teeth (220) each corresponding to the plurality of yokes (210), wherein each tooth (220) of the plurality of teeth (220) extends from the corresponding yoke (210) of the plurality of yokes (210) toward the rotor (150); and A plurality of electrical steel plates (200b, 200d), each of which has a yoke shape corresponding to each of the plurality of yokes (210) and a tooth shape corresponding to each of the plurality of teeth (220), A vacuum cleaner in which the plurality of electrical steel plates (200b, 200d) are laminated through an adhesive layer (250) between two adjacent electrical steel plates among the plurality of electrical steel plates (200b, 200d) to form the stator core (200, 200-1).

2. In paragraph 1, Each of the above plurality of electrical steel plates (200d) is A cleaner comprising an interlocking portion (260) having an embossing structure for laminating the plurality of electrical steel plates (200d) so that the interlocking portions (260) of adjacent electrical steel plates among the plurality of electrical steel plates (200d) are interlocked in the interlocking portion (260).

3. In paragraph 2, The above interlocking part (260) is A protrusion (261) from the first surface (200da); and Includes a concave portion (262) from the second surface (200db) opposite to the first surface (200da), The above protrusion (261) is a cleaner that protrudes into a concave portion (262) of an adjacent electrical steel plate among the plurality of electrical steel plates (200d) in the laminate of the plurality of electrical steel plates (200d).

4. In paragraph 2 or 3, The above interlocking part (260) is arranged in at least one of at least one yoke shape or at least one tooth shape, the cleaner.

5. In any one of paragraphs 2 to 4, A cleaner in which, for each electrical steel plate among the plurality of electrical steel plates (200d), the number of the interlocking parts (260) is less than the sum of the number of the yoke shapes and the number of the tooth shapes.

6. In any one of paragraphs 2 to 5, The above interlocking part (260) is a vacuum cleaner including two or more interlocking parts (260).

7. In any one of paragraphs 1 to 6, The above stator core (200, 200-1) includes a bending portion (240) that connects adjacent yokes (210) among the plurality of yokes (210), The above bending portion (240) is bent toward the center of the stator core (200, 200-1) so that the stator core (200, 200-1) has a ring shape, a vacuum cleaner.

8. In any one of paragraphs 1 to 7, The above adhesive layer (250) is a vacuum cleaner comprising a thermosetting adhesive.

9. In any one of paragraphs 1 to 8, The width of each yoke (210) among the above plurality of yokes (210) is 1 to 3 mm, A vacuum cleaner, wherein each of the plurality of teeth (220) has a width of 0.5 to 3 mm.

10. In any one of paragraphs 1 to 9, The above stator core (200, 200-1) has a ring shape, A vacuum cleaner, wherein each yoke (210) among the plurality of yokes (210) has an outer diameter of 20 to 40 mm.

11. In any one of paragraphs 1 to 10, The above stator core (200, 200-1) has a ring shape, A vacuum cleaner, wherein each of the plurality of teeth (220) has an inner diameter of 5 to 20 mm.

12. In a stator (140) including a stator core (200, 200-1), The above stator core (200, 200-1) is A plurality of yokes (210) circumferentially surrounding the center of the stator core (200, 200-1); A plurality of teeth (220) each corresponding to the plurality of yokes (210), wherein each tooth (220) of the plurality of teeth (220) extends from the corresponding yoke (210) of the plurality of yokes (210) to the center; and A plurality of electrical steel plates (200b, 200d), each of which has a yoke shape corresponding to each of the plurality of yokes (210) and a tooth shape corresponding to each of the plurality of teeth (220), A stator in which the plurality of electrical steel plates (200b, 200d) are laminated through an adhesive layer (250) between two adjacent electrical steel plates among the plurality of electrical steel plates (200b, 200d) to form the stator core (200, 200-1).

13. A method for manufacturing a stator (140) including a plurality of yokes (210) in which adjacent yokes are connected to each other through a bending portion (240), a plurality of teeth (220) corresponding to the plurality of yokes (210) and each extending from a corresponding yoke among the plurality of yokes (210), and a plurality of electrical steel plates (200b, 200d) each having a yoke shape corresponding to each of the plurality of yokes (210) and a tooth shape corresponding to each of the plurality of teeth (220), By cutting a plurality of electrical steel plates, the yoke shape and the tooth shape are formed on each of the plurality of electrical steel plates (200b, 200d), Applying an adhesive (G) to at least one surface of the above-mentioned cut electrical steel plates (200b, 200d), The above-mentioned cut plurality of electrical steel plates (200b, 200d) are laminated so that the adhesive layer (G) is positioned between two adjacent electrical steel plates among the plurality of electrical steel plates (200b, 200d) to form an assembled stator (200', 200-1'). The assembled stator (200', 200-1') is heated to harden the applied adhesive layer (G), An insulator (143) is formed by injecting an insulating material into at least a portion of each tooth among a plurality of teeth (220) of an assembled stator (200', 200-1'), Wind the stator coil (145) around the above insulator (143), A method for manufacturing a stator, wherein the above bending portion (240) is bent to form the above stator core (200', 200-1') into a ring shape.

14. In paragraph 13, A method for manufacturing a stator, wherein an interlocking portion (260) is embossed on each of the plurality of electrical steel plates (200b) so that the interlocking portions (260) of adjacent electrical steel plates (200b) interlock when stacked.

15. In paragraph 13 or 14, A method for manufacturing a stator, wherein the heating is performed simultaneously with the lamination or after the lamination is completed.

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