Brushless motor, stator, stator manufacturing method and brushless motor manufacturing method

Patent metadata

Field	Value
Publication number	US-9806566-B2
Application number	US-201313972914-A
Country	US
Kind code	B2
Filing date	Aug 22, 2013
Priority date	Aug 30, 2012
Publication date	Oct 31, 2017
Grant date	Oct 31, 2017

Abstract

A brushless motor comprising: a rotor; a stator core disposed at a radial direction outside of the rotor, and a stator case. The stator core includes an outer ring shaped section, teeth sections projecting out from the outer ring shaped section toward a radial direction inside, and an inner ring shaped section extending from end portions of the teeth sections. Protruding portions are formed at the outer ring shaped section so as to project toward a radial direction outside and so as to be disposed at even intervals around a circumferential direction of the outer ring shaped section. The stator case is integrated together with the stator core by a plurality of plastic deformation portions formed at an outer peripheral portion of the stator case at locations facing towards the protruding portions, and the plastic deformation portions are disposed at even intervals along a circumferential direction of the stator case.

First claim

What is claimed is:

1. A brushless motor comprising:
a rotor that includes a rotation shaft section that is supported so as to be rotatable about its axial line and magnets that are disposed along a circumferential direction of the rotation shaft section;
a stator core that is disposed at a radial direction outside of the rotor, and that includes:
an outer ring shaped section that is formed in a ring shape,
teeth sections that project out from the outer ring shaped section toward a radial direction inside of the outer ring shaped section and are wound with conductive wire coils, and
an inner ring shaped section that is configured by rotor-side faces that extend along a rotor circumferential direction from end portions of the teeth sections, the end portions being adjacent to the rotor, wherein the rotor-side faces configure circular arc shaped faces with the rotor as the axial center,
wherein protruding portions are formed at the outer ring shaped section so as to project toward a radial direction outside of the outer ring shaped section and so as to be disposed at even intervals around a circumferential direction of the outer ring shaped section as viewed along an axial direction of the outer ring shaped section; and

a stator case that is formed in a cylindrical shape so as to cover the stator core from a radial direction outside of the stator core and that is integrated together with the stator core by a plurality of plastic deformation portions formed at an outer peripheral portion of the stator case at locations facing towards the protruding portions, wherein the plurality of plastic deformation portions are disposed at even intervals along a circumferential direction of the outer peripheral portion as viewed along the axial direction of the outer ring shaped section,
wherein the outer ring shaped section is configured from a plurality of yoke configuration sections that configure a ring shaped yoke and that are segmented in a circumferential direction of the yoke, with the teeth sections respectively projecting out from the yoke configuration sections toward inside in a yoke radial direction,
wherein the stator case is integrated together with a plurality of core configuration sections, each of the plural core configuration sections being equipped with one of the yoke configuration sections and one of the teeth sections,
wherein the stator core further comprises a plurality of insulators, and each of the insulators comprises a plurality of insulating portions and connection portions, the insulating portions being integrated with the respective core configuration sections and insulating between the respective teeth sections and the winding portions, and each of the connection portions being formed in a ring shape and connecting together the plurality of insulating portions,
wherein the plurality of insulators are configured such that rigidities of all of the connection portions of all of the insulators are substantially the same, and
wherein the rigidities of the plurality of connection portions are adjusted so as to be substantially the same as each other by selecting materials for the respective connection portions such that Young's modulus of the material of one of the connection portions out of the connection portions is lower than Young's modulus of the material of another of the connection portions that is disposed outside in the radial direction of the one connection portion.

2. The brushless motor of claim 1 , wherein the protruding portions are provided at locations of the outer ring shaped section, the locations facing toward the stator case.

3. The brushless motor of claim 1 , wherein 3×n individual or 4×n individual plastic deformation portions are formed at the outer peripheral portion of the stator case, wherein n is an integer greater than or equal to 1.

4. The brushless motor of claim 1 , wherein:
the stator core is configured with a segmented structure configured by arraying m individual core configuration sections in a ring shape; and
there are m×n individual plastic deformation portions formed at the outer peripheral portion of the stator case, wherein each of m and n independently represents an integer greater than or equal to 1.

5. The brushless motor of claim 1 , wherein:
the connection portions of the plurality of insulators are disposed so as to be adjacent to each other in a radial direction of the insulators, and the rigidities of the plurality of connection portions are adjusted so as to be substantially the same as each other by adjusting at least one factor from the group consisting of wall thickness in the axial direction, wall thickness in the radial direction, and cross-section profile of each of the connection portions.

6. The brushless motor of claim 1 , wherein:
the rigidities of the plurality of connection portions are adjusted so as to be substantially the same as each other by providing at least one of the connection portions out of the plurality of connection portions with a radial direction extending rib.

7. The brushless motor of claim 1 , wherein:
the rigidities of the plurality of connection portions are adjusted so as to be substantially the same as each other by providing a notch in at least one of the connection portions out of the plurality of connection portions.

8. The brushless motor of claim 1 , wherein:
the rigidities of the plurality of connection portions are adjusted so as to be substantially the same as each other by disposing the connection portions adjacent to each other in an axial direction of the connection portions and making the cross-section profile of each of the connection portions the same as each other.

Assignees

• Asmo Co Ltd

Inventors

• Nagao Yoshinobu
• Suzuki Satoru
• Nagaya Takashi
• Adachi Yoshihiro
• Ishino Yukihide
• Nakagawa Yoshitsugu
• Irie Masaru
• Matsuura Toshihiro

Classifications

• H02K1/148 Primary

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

• H02K1/14

  Stator cores with salient poles · CPC title

• H02K1/185

  to outer stators · CPC title

• Y10T29/49009

  Dynamoelectric machine · CPC title

• H02K3/522

  for generally annular cores with salient poles · CPC title