Amorphous stator, and electric motor using same

Patent metadata

Field	Value
Publication number	US-9318927-B2
Application number	US-201213981156-A
Country	US
Kind code	B2
Filing date	Jan 19, 2012
Priority date	Jan 24, 2011
Publication date	Apr 19, 2016
Grant date	Apr 19, 2016

Abstract

Provided is an amorphous stator for use in a high-power, high-speed electric motor, and an electric motor using the amorphous stator, in which amorphous alloy powder is compressed and molded into a number of unit split cores, to then be assembled with bobbins, and to thus be easily molded into a core of a complex shape, and a core loss is minimized by using the amorphous alloy powder, to thus promote improvement of an efficiency of the motor. The electric motor includes: a stator in which a coil is wound on bobbins respectively formed in a number of unit split cores, and the number of unit split cores are assembled in an annular form by an integral or split bobbin; and a rotor that is rotated by an interaction with the stator, wherein the unit split cores are molded with mixed powder made of plate-shaped amorphous alloy powder and spherical soft magnetic powder.

First claim

The invention claimed is:

1. An amorphous stator for use in an electric motor, the amorphous stator comprising:
a number of unit split core assemblies that are temporarily assembled in an annular form; and
an annular support bracket that are coupled at one side surface of the number of the assembled unit split core assemblies, to thus fix the number of the unit split core assemblies,
wherein each of the number of unit split core assemblies comprises:
a number of unit split cores that are made in an “I”-shape by compression molding amorphous alloy powder;
a number of insulating bobbins that comprise inner and outer flanges that are formed in the outer periphery of the number of unit split cores, to thus define a coil winding area, in which a first coupling protrusion and a coupling ring that are formed at both ends of the outer flange interconnect with each other to then be assembled in an annular form, and that are fixed to the outer side of the annular support bracket by a second coupling protrusion that extends in a direction opposed to the first coupling protrusion and fixed to the inner side of the annular support bracket by a pair of third coupling protrusions that are formed at both sides of the inner flange; and
a coil that is wound on the coil winding area of the insulating bobbins.

2. The amorphous stator for use in an electric motor, according to claim 1 , wherein the annular support bracket comprises:
an inner ring and an outer ring that are arranged in a concentric circle of different diameters; and
a number of connecting links that are radially disposed at a distance to connect the inner ring and the outer ring, and
wherein each connecting link comprises: a first throughhole through which the second coupling protrusions are inserted and combined; and a pair of second throughhole through which a pair of third coupling protrusions are inserted and combined.

3. The amorphous stator for use in an electric motor, according to claim 2 , wherein a boss at the center portion of which a throughhole is formed protrudes at the first and second throughholes of the connecting links, and
the second and third coupling protrusions are coupled to the bosses of the annular support bracket and the distal ends thereof are ultrasonically fused or thermally fused.

4. The amorphous stator for use in an electric motor, according to claim 1 , wherein the bobbin comprises:
a first coupling protrusion formed on one side of the outer flange;
a coupling ring formed on the other side of the outer flange and coupled to the first coupling protrusion of the adjacent bobbin;
a second coupling protrusion that extends in opposition to the first coupling protrusion and whose distal end is fixed to the annular support bracket; and
a pair of third coupling protrusions formed at one and other sides of the inner flange and whose distal ends are fixed to the annular support bracket.

5. The amorphous stator for use in an electric motor, according to claim 1 , wherein the number of unit split cores are molded by a mixture of plate-shaped amorphous alloy powder and spherical soft magnetic powder, to thus promote improved permeability and improved packing density.

Assignees

• Kim Byoung Soo
• Amotech Co Ltd

Inventors

• Kim Byoung Soo

Classifications

• H02K1/02 Primary

  characterised by the magnetic material · CPC title

• H02K1/148

  Sectional cores (H02K1/141 takes precedence) · CPC title

• H02K1/187

  to inner stators · CPC title

• H02K21/12

  with stationary armatures and rotating magnets · CPC title

• H02K2213/03

  Machines characterised by numerical values, ranges, mathematical expressions or similar information · CPC title