Axial-air-gap motor and bobbin for motor

Patent metadata

Field	Value
Publication number	US-10630120-B2
Application number	US-201415129716-A
Country	US
Kind code	B2
Filing date	Dec 19, 2014
Priority date	Mar 28, 2014
Publication date	Apr 21, 2020
Grant date	Apr 21, 2020

Abstract

An axial-air-gap motor integrally configured by resin molding, a plurality of stator cores being arranged in an annular configuration, wherein the resin is spread in an efficient manner. An axial-air-gap motor, provided with: a plurality of stator cores, a stator, and one or more rotors. The stator cores are provided with a teeth iron core having the shape of an approximate trapezoidal cylinder, a bobbin covering at least the vicinity of both end parts of the outer periphery of the teeth iron core, flange parts provided in the vicinity of the portions of the bobbin that cover the both end parts of the outer periphery of the teeth iron core so as to extend for a predetermined length in a direction perpendicular to the outer periphery of the teeth iron core, and at least one protrusion further extending from the tip of the flange part in the direction of extension. The extension-direction tip of each of the protrusions is brought into contact, in the direction of rotation of an output shaft, with the extension-direction end part of the flange part of another stator core, the stator cores being arranged in an annular shape about the axial direction of the output shaft. The stator cores are integrally molded using a resin to form the stator. The one or more rotors are in a planar-faced configuration with the side surfaces of the end part of the teeth iron core, interposed by a predetermined air gap.

First claim

The invention claimed is:

1. An axial-air-gap motor comprising:
a plurality of stator cores each including:
a teeth iron core having a shape of a pillar, and
a bobbin covering at least a vicinity of both end parts of the outer periphery of the teeth iron core, the bobbin having flange parts provided in a vicinity of the portions of the bobbin that cover both the end parts of the outer periphery of the teeth iron core so as to extend by a predetermined length in a direction perpendicular to the outer periphery of the teeth iron core, and at least one protrusion having a rectangular shape further extending from a tip of the flange parts in the extension direction, a radially inner-facing surface of the at least one protrusion of the bobbin being arranged in contact with a radially outer-facing surface of the at least one protrusion of an adjacent bobbin;

a stator that is formed by integrally molding the plurality of stator cores by a resin, the stator cores being configured such that a gap is formed in a rotational direction of each flange part by bringing the extension-direction tip of the at least one protrusion in the flange part of the bobbin of one stator core into contact, in a rotational direction of an output shaft, with an end part of the flange part of the bobbin of another stator core in the extension direction and being arranged in an annular shape about an axial direction of the output shaft; and
one or more of rotors that are in a planar-faced configuration with the side surfaces of the end part of the teeth iron core, interposed by a predetermined air gap.

2. The axial-air-gap motor according to claim 1 , wherein the bobbin includes at least the one protrusion on each of both the flange parts extending in the rotational direction of the output shaft, and
a distance from a side face of the one protrusion in the axial direction of the output shaft to a shaft core is as approximately equal as a distance from a side face of the other protrusion in a direction opposing the axial direction of the output shaft to the shaft core.

3. The axial-air-gap motor according to claim 2 , wherein the bobbin includes at least the two protrusions on each of the flange parts extending in the rotational direction of the output shaft, and
a distance from a side face of each of at least the two protrusions of the one flange part in the axial direction of the output shaft to the shaft core is as approximately equal as a distance from a side face of at least the two protrusions of the other flange part in a direction opposing the axial direction of the output shaft to the shaft core.

4. The axial-air-gap motor according to claim 1 , wherein the bobbin includes at least the two protrusions on each of both the flange parts extending in the rotational direction of the output shaft, and
at least one of the two protrusions on each of both the end parts is positioned in the vicinity of a shaft core-side end part in each of both the end parts, and the other one is positioned in the vicinity of a radial-outside end part in each of both the end parts.

5. The axial-air-gap motor according to claim 1 , wherein the bobbin includes a concave part having a width as approximately equal as an axial-direction width of the protrusion and a depth shorter than an extension-direction length of the protrusion on the opposing flange part in the rotational direction of the output shaft, and
a distance of the protrusion from a shaft core of the output shaft is as approximately equal as a distance of the concave part from the shaft core of the output shaft.

6. The axial-air-gap motor according to claim 1 , wherein the bobbin includes at least the one protrusion on each of the flange parts opposing in the rotational direction of the output shaft,
a distance of the one flange part protrusion from a shaft core of the output shaft is as approximately equal as a distance of the other flange part protrusion from the shaft core of the output shaft, and
the stator causes an extension-direction tip of each of the protrusions to be brought into contact with an extension-direction end part of the protrusion of the other stator core along the rotational direction of the output shaft.

7. The axial-air-gap motor according to claim 6 , wherein the bobbin includes a convex part extending in the rotational direction in a tip of the one flange part protrusion, and a concave part in a tip of the other flange part protrusion, the concave part having a depth as approximately equal as a radial width of the convex part and as approximately equal as or longer than a rotational direction length of the convex part.

8. A bobbin for a motor stator in which teeth iron cores each having a side cross-sectional surface in an approximate trapezoidal shape are arranged in an annular shape by opposing two oblique sides of the teeth iron core to each other and pointing an upper base side thereof at the center, including
an inner cylindrical part having an inner diameter as approximately equal as an outer peripheral shape of the teeth iron core for inserting the teeth iron core therein,
an outer cylindrical part around which a coil is wound along and on an outer periphery of the teeth iron core, and
a flange part extending by a predetermined length in an opposing direction of the two oblique sides from a peripheral surface of the outer cylindrical part, wherein the flange part includes at least one protrusion having a rectangular shape further extending from the extension direction of the flange part, wherein an extension-direction tip of the at least one protrusion is brought into contact with an extension-direction tip of at least one protrusion of an adjacent bobbin so as to form a gap in a rotational direction between the flange part of the bobbin and a flange part of the other bobbin, a radially inner-facing surface of the at least one protrusion of the bobbin being arranged in contact with a radially outer-facing surface of the at least one protrusion of the adjacent bobbin.

9. An axial-air-gap motor comprising:
a plurality of stator cores each including:
a teeth iron core having a shape of a pillar,
a bobbin covering at least a vicinity of both end parts of the outer periphery of the teeth iron core,
flange parts provided in a vicinity of the portions of the bobbin that covers both the end parts of the outer periphery of the teeth iron core so as to extend by a predetermined length in a direction perpendicular to the outer periphery of the teeth iron core, and
at least one protrusion having a rectangular shape further extending from a tip of the flange part in the extension direction, a radially inner-facing surface of the at least one protrusion of the bobbin being arranged in contact with a radially outer-facing surface of the at least one protrusion of an adjacent bobbin;

a stator in which the plurality of stator cores are integrally molded by a resin, the stator cores being configured such that flange parts of bobbins of adjacent stator cores have an air gap therebetween, and the extension-direction tip of the at least one protrusion in the flange part of the bobbin of one stator core is brought into contact, in a rotational direction of an output shaft, with the extension-direction tip of the at least one protrusion in the flange part of the bobbin of another stator core and being arranged in an annular shape about an axial direction of the output shaft; and
one or more of rotors that are in a planar-faced configuration with the side surfaces of the end part of the teeth iron core, interposed by a predetermined air gap.

10. The axial-air-gap motor according to claim 9 , wherein the bobbin includes a convex part extending in the rotational direction in a tip of th

Assignees

• Hitachi Industry Equipment Systems Co Ltd

Inventors

• Sakai Toru
• Yamazaki Katsuyuki

Classifications

• H02K1/182 Primary

  to stators axially facing the rotor, i.e. with axial or conical air gap · CPC title

• H02K3/46

  Fastening of windings on the stator or rotor structure · CPC title

• H02K3/521

  applicable to stators only · CPC title