Motor, end cap and manufacturing method thereof

Patent metadata

Field	Value
Publication number	US-11101712-B2
Application number	US-201816032965-A
Country	US
Kind code	B2
Filing date	Jul 11, 2018
Priority date	Jul 11, 2017
Publication date	Aug 24, 2021
Grant date	Aug 24, 2021

Abstract

An electric motor, an end cap thereof and a manufacturing method of the end cap are provided. The end cap includes an insulating body and a filter circuit board mounted to the insulating body. The filter circuit board includes at least two power conductors for receiving an external power source, an insulating support frame integral with the at least two power conductors, and at least one filter element. One end of the at least one filter element is connected to a corresponding power conductor, and the other end of the at least one filter element is grounded.

First claim

The invention claimed is:

1. An end cap of an electric motor, comprising an insulating body, wherein the end cap further comprises a filter circuit board mounted to the insulating body, the filter circuit board comprising:
two power conductors, for receiving an external power source,
an insulating support frame integral with the at least two power conductors, and
at least one filter element, one end of the at least one filter element being connected to a corresponding power conductor, the other end of the at least one filter element being grounded,
wherein the insulating body is substantially cylindrical which has a dividing wall which divides the insulating body into two parts in an axial direction of the end cap, the filter circuit board and a brush assembly are respectively accommodated in the two parts of the insulating body.

2. The end cap according to claim 1 , wherein the filter circuit board further comprises at least one grounding conductor configured to be grounded, and the at least one filter element is grounded by connecting the at least one grounding conductor.

3. The end cap according to claim 1 , wherein the filter circuit board is substantially in the shape of a flat plate, the two power conductors are metal sheets substantially parallel to the filter circuit board.

4. The end cap according to claim 1 , wherein the insulating support frame comprises at least one mounting groove for mounting the at least one filter element.

5. The end cap according to claim 1 , further comprising a pair of power terminals fixed by the insulating body, for connection the external power source.

6. The end cap according to claim 1 , wherein each power conductor has an in inserting hole, and each power terminal has an inserting portion being inserted into a corresponding inserting hole.

7. The end cap according to claim 1 , wherein the dividing wall has at least one recess, for arranging at least one inductor.

8. The end cap according to claim 1 , wherein the brush assembly comprises at least two brushes, and the insulating body further comprises at least one isolation rib extending along a radial direction of the end cap and arranged between the two brushes.

9. An electric motor, comprising a rotor and a stator, wherein the stator comprises a filter circuit board mounted into the electric motor, the filter circuit board comprising:
two power conductors, for receiving an external power source,
an insulating support frame integral with the at least two power conductors, and
at least one filter element, one end of the at least one filter element being connected to a corresponding power conductor, the other end of the at least one filter element being grounded,
wherein the stator comprises a housing with an open end, an end cap with a brush assembly, the end cap is at least partially disposed inside the open end of the housing, and the filter circuit board is supported by the end cap,
wherein the end cap is substantially cylindrical which has a dividing wall which divides the end cap into two parts in an axial direction, the filter circuit board and the brush assembly are respectively accommodated in the two parts of the end cap.

10. The electric motor according to claim 9 , wherein the filter circuit board further comprises at least one grounding conductor configured to be grounded, and the at least one filter element is grounded by connecting the at least one grounding conductor.

11. The electric motor according to claim 9 , wherein the filter circuit board is substantially in the shape of a flat plate, the two power conductors are metal sheets substantially parallel to the filter circuit board.

12. The electric motor according to claim 9 , wherein the stator comprises a housing with an open end, a metal cover is mounted to the open end of the housing, and the filter circuit board is supported by the metal cover.

13. A manufacturing method of an end cap of an electric motor, comprising:
preparing a filter circuit board, comprising:
forming two power conductors for receiving an external power source;
molding an insulating support frame on the two power conductors; and
connecting at least one filter element to a corresponding power conductor; and

mounting the filter circuit board to an insulating body,
wherein the insulating body is substantially cylindrical which has a dividing wall which divides the insulating body into two parts in an axial direction of the end cap, the filter circuit board and a brush assembly are respectively accommodated in the two parts of the insulating body.

14. The manufacturing method according to claim 13 , wherein the step of forming conductors comprises forming an integral conductor frame having two power conductors.

15. The manufacturing method according to claim 13 , wherein the step of mounting the filter circuit board to an insulating body further comprises respectively connecting the power conductors to two power terminals fixed by the insulating body.

16. The manufacturing method according to claim 13 , further comprising mounting an insulating sheet to the insulating body for covering the filter circuit board; and mounting a metal cover to the insulating body.

Assignees

• Johnson Electric Int Ag

Inventors

• Yeung Yukwai
• Lau Chingsik
• Zhou Dawei
• Tam Siukin
• Fu Tao

Classifications

• H02K23/66 Primary

  Structural association with auxiliary electric devices influencing the characteristic of, or controlling, the machine, e.g. with impedances or switches · CPC title

• H02K5/145

  Fixedly supported brushes or brush holders, e.g. leaf or leaf-mounted brushes · CPC title

• H02K11/40

  Structural association with grounding devices · CPC title

• H02K5/14

  Means for supporting or protecting brushes or brush holders · CPC title

• H02K5/08 Primary

  Insulating casings · CPC title