Brushless motor and stator therefor

Patent metadata

Field	Value
Publication number	US-2018366996-A1
Application number	US-201816011823-A
Country	US
Kind code	A1
Filing date	Jun 19, 2018
Priority date	Jun 20, 2017
Publication date	Dec 20, 2018
Grant date	—

Abstract

A brushless motor comprising a frame; a rotor assembly comprising a shaft, a rotor core and a bearing assembly, the bearing assembly being mounted to the frame; and at least one stator comprising a C-shaped stator core, the stator core comprising a back and first and second arms, wherein at least one of the first and second arms includes a protrusion that contacts the frame so as to inhibit radial movement of the stator core towards the rotor assembly.

First claim

What is claimed is:

1 . A brushless motor comprising:
a frame; a rotor assembly comprising a shaft, a rotor core and a bearing assembly, the bearing assembly being mounted to the frame; and at least one stator comprising a C-shaped stator core, the stator core comprising a back and first and second arms; wherein at least one of the first and second arms includes a protrusion that contacts the frame so as to inhibit radial movement of the stator core towards the rotor assembly.

2 . The brushless motor of claim 1 , wherein the frame is shaped so as to allow the at least one stator to slide radially towards the rotor assembly until the protrusion contacts the frame.

3 . The brushless motor of claim 2 , wherein the frame includes a slot into which at least a portion of the stator is inserted, and the protrusion contacts at least one edge of the slot.

4 . The brushless motor of claim 3 , wherein the frame includes a plurality of slots, and at least a portion of a respective one of a plurality of stators is inserted into each slot.

5 . The brushless motor of claim 1 , wherein the rotor assembly includes an impeller, and the frame includes an impeller shroud.

6 . The brushless motor of claim 1 , wherein the bearing assembly comprises a pair of bearings mounted to either side of the rotor core on the shaft.

7 . The brushless motor of claim 1 , wherein the stator core comprises a plurality of layers or laminations held together by a weld located within or adjacent to the at least one protrusion.

8 . The brushless motor of claim 1 , wherein each arm of the stator core includes a respective protrusion, each protrusion contacts the frame, and the stator core comprises a plurality of layers or laminations held together by a respective weld located within or adjacent to each of the protrusions.

9 . The brushless motor of claim 1 , wherein the protrusion extends along the axial length of the stator core.

10 . The brushless motor of claim 1 , wherein the stator includes a bobbin and a winding wound round the back of the stator core.

11 . The brushless motor of claim 1 , wherein each arm of the stator core comprises a straight section that extends from the back to a respective pole tip.

12 . A C-shaped stator core for a brushless motor, the stator core comprising a back and first and second arms, at least one of the first and second arms including a protrusion, wherein the stator core is formed of a plurality of layers, the layers held together by a weld located within or adjacent to the protrusion.

13 . The stator core of claim 12 , wherein each arm of the stator core includes a respective protrusion, and the stator core comprises a plurality of layers or laminations held together by a respective weld located within each of the protrusions.

14 . The stator core of claim 12 , wherein the protrusion extends along the axial length of the stator core.

15 . A brushless motor comprising:
a frame; a rotor assembly comprising a shaft, a rotor core and a bearing assembly, the bearing assembly being mounted to the frame; and at least one stator comprising a C-shaped stator core, wherein the C-shaped stator core includes a back and first and second arms, at least one of the first and second arms including a protrusion, wherein the stator core is formed of a plurality of layers, the layers held together by a weld located within or adjacent to the protrusion.

Assignees

• Dyson Technology Ltd

Inventors

• Celik Tuncay
• Warne David George

Classifications

• H02K5/161

  radially supporting the rotary shaft at both ends of the rotor (H02K5/165, H02K5/167, H02K5/173 take precedence) · CPC title

• H02K1/17

  Stator cores with permanent magnets · CPC title

• H02K1/141 Primary

  consisting of C-shaped cores · CPC title

• H02K21/18

  having horse-shoe armature cores (with homopolar co-operation H02K21/20) · CPC title

• H02K1/2706

  Inner rotors · CPC title