Electric blower using an electric motor using a plurality of stator cores and vacuum cleaner using this electric blower
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Solution Overview
Problem
The existing brushless DC motors for electric blowers, such as those used in stick-type vacuum cleaners, face reliability issues due to thermal and mechanical loads applied to the coils during the molding of resinous bridge portions between stator cores, which can degrade performance.
Innovation Solution
The configuration includes stator cores with spacers made of non-magnetic material, such as PBT, that press the stator cores against a frame, maintaining their position and preventing coil damage, while allowing for easier assembly and improved reliability by avoiding direct molding of the bridge portion over the coils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If resinous bridge portions are molded between stator cores to connect and integrate them, then assemblability is improved, but thermal load and mechanical load are applied to the coil causing reliability degradation
Solution Approach 1:
The stator is divided into multiple independent stator cores that are not connected by molded bridge portions. Each stator core remains as a separate unit with coils wound thereon, eliminating the need for resinous bridge portions that would apply thermal and mechanical loads to the coils. This segmentation approach maintains assemblability while protecting coil integrity.
Solution Approach 2:
A non-magnetic spacer is introduced as an intermediary component between stator cores to maintain their positional relationships without creating direct mechanical or thermal connections. The spacer prevents harmful loads from being transmitted to the coils while still achieving the integration function needed for assembly.
2Ease of manufacture
If stator cores are divided into multiple segments to improve workability of coil winding, then coil workability is improved, but additional connection structures are required increasing device complexity
Solution Approach 1:
The stator is segmented into multiple independent stator cores, allowing coil winding to be performed on each core separately with improved workability. The segmentation itself is the final structure - no additional bridge portions or connection structures are needed, as the stator cores function independently while maintaining their segmented configuration.
Solution Approach 2:
The harmful connection function (molded bridge portions) is extracted from the stator structure. The stator cores are divided into segments for manufacturing convenience, but the connection function is removed entirely, replacing it with a simpler arrangement where cores are positioned using spacers rather than being permanently bonded together.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances the reliability and assemblability of the motor by preventing load application on the coils and allowing for precise positioning of stator cores, improving the motor's operational stability and efficiency.
Implementation Method 1
spacers made of non-magnetic material, such as PBT, that press the stator cores against a frame
Implementation Method 2
a brushless DC motor is known as an electric motor for an electric blower using a battery as a power source
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
An electric blower comprising: an electric motor; and a fan rotated by the electric motor, wherein the electric motor includes a stator, a rotor connected to the fan, and a frame accommodating the stator and the rotor, the stator includes a plurality of stator cores respectively having a core tooth portion facing the rotor, a coil portion attached to the stator core to form a magnetic pole at the core tooth portion, and a spacer inserted between the stator cores to press the stator cores against the frame, and the frame includes a regulation portion regulating position of the stator core pressed by the spacer.