ELECTRIC MOTOR

Abstract

A bobbin for supporting a winding on electric motor stator laminations includes a first flange member and a second flange member substantially parallel to the first flange member. A winding hub includes an inner hub portion coupled to the first flange member and a flared portion connecting the inner hub portion to the second flange member such that a winding span defined between the first flange member and the flared portion tapers from the second flange member to the inner hub portion. An inner surface of the winding hub defines a bobbin aperture for receiving stator laminations of the motor. A rib member is coupled to the inner surface and extends into the aperture for engaging the laminations.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 61/587482, filed Jan. 17, 2012, the contents of which are herein incorporated by reference.

BACKGROUND

The present invention relates to electric motors, such as a brushless DC (BLDC) motor. Electric motors include a rotor that is rotatably supported in a housing by one or more bearings. A stator is fixed to the housing and surrounds a portion of the rotor. Stator windings provide an electro-magnetic field to the rotor. The housing protects and supports the rotor and stator.

SUMMARY

In one embodiment, the invention provides a bobbin for supporting a winding on electric motor stator laminations. The bobbin includes a first flange member and a second flange member substantially parallel to the first flange member. A winding hub includes an inner hub portion coupled to the first flange member and a flared portion connecting the inner hub portion to the second flange member such that a winding span defined between the first flange member and the flared portion tapers from the second flange member to the inner hub portion. An inner surface of the winding hub defines a bobbin aperture for receiving stator laminations of the motor. A rib member is coupled to the inner surface and extends into the aperture for engaging the laminations.

Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a motor assembly.

FIG. 2 is an alternative perspective view of the motor assembly of FIG. 1.

FIG. 3 is a cross-sectional view along line 3-3 of the motor assembly of FIG. 1.

FIG. 4 is a cross-sectional view along line 4-4 of the motor assembly of FIG. 2.

FIG. 5 is a perspective view of a rotor assembly, a stator assembly, and a printed circuit board of the motor assembly of FIG. 1.

FIG. 6 is a perspective view of a bobbin of the stator of FIG. 5.

FIG. 7 is a cross-sectional view along section line 7-7 of the bobbin of FIG. 6.

FIG. 8 is a cross-sectional view along section line 8-8 of the bobbin of FIG. 6, including an exemplary stator winding arrangement.

FIG. 9 is an exploded view of a bearing assembly.

FIG. 10 is a cross sectional view of a bearing spring of the bearing assembly of FIG. 9.

FIG. 11 is a detailed view of a portion of FIG. 3, illustrating a bearing assembly and bearing seat.

FIG. 12 is a front view of a motor housing cover according to another aspect of the invention.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

Referring to FIG. 3, a motor 10 includes a stator assembly 14, a rotor assembly 18, a housing cover 22, and a housing case 26. The motor 10 may be, for example, a single phase, four pole brushless DC (BLDC) motor.

Referring to FIG. 1, the housing cover 22 includes a cover body 30. The cover body 30 defines a shaft aperture 34 disposed about a rotor shaft axis 38. Three cover assembly lugs 42 extend outwardly from edges of the cover body 30. Referring to FIG. 2, the three cover assembly lugs 42 align with corresponding case assembly lugs 46 defined by the housing case 26. The housing cover 22 may be joined to the housing case 26 with fasteners 48 extending across the assembly lugs 42 and 46. The housing case 26 further includes three mounting lugs 50 disposed circumferentially about the shaft axis 38, approximately 120 degrees apart. Each mounting lug 50 defines a mounting aperture 54 for receiving, for example, a self-tapping mounting screw.

Referring to FIG. 3, each of the housing cover 22 and the housing case 26 defines a bearing seat 58 and 62, respectively. Referring to FIG. 11, housing case bearing seat 62 defines a thrust support surface 66, a sleeve bearing support surface 70, a pad support surface 74, a spring support surface 78, and a spring centering surface 82. The thrust support surface 66, the pad support surface 74, and the spring support surface 78 are substantially perpendicular to the shaft axis 38 (FIG. 3). Referring to FIG. 11, the spring centering surface 82 is substantially perpendicular to the spring support surface 78. The sleeve bearing surface 70 is substantially oblique to the pad support surface 74.

Each of the housing cover 22 and the housing cover 26 may be unitarily formed by, for example, injection molding a thermoplastic.

Referring to FIG. 5, the stator assembly 14 includes a laminate core 86 (i.e., stator core) and a coil assembly 90. The laminate core includes a stack of wafer-like laminations 94. Referring to FIG. 4, each lamination 94 includes an outer ring 98 and four substantially radial teeth 102. In the illustrated construction, the outer ring 98 is divided into four ring segments 104. The ring segments 104 are coupled together with portions of the radial teeth 102.

Referring to FIG. 4, the coil assembly 90 includes four bobbins 106. As illustrated in FIGS. 4-5, the bobbins 106 are arranged circumferentially about the shaft axis 38. Referring to FIG. 7, each bobbin 106 includes bobbin body 110 having a winding hub 114, an inner flange 118, and an outer flange 122.

The winding hub 114 includes an inner hub portion 124 adjacent the outer flange 122 and a flared portion 126 adjacent the inner flange 118. A winding span 130, defined between the flared portion 126 and the outer flange 122, tapers from an outer portion 134 of the bobbin body 110 from inner flange the 118 to inner hub portion 124. As illustrated in FIG. 7, this arrangement provides for a long winding span 130 away from the winding hub 114 and a short winding span 130 adjacent the inner hub portion 124.

Referring to FIG. 6, an inner surface 135 of the winding hub 114 defines a rectangular aperture 136 through the bobbin body 110. The rectangular aperture 136 is configured to receive the radial teeth 102 of the laminations 94 (see FIG. 4). Referring to FIG. 6, a rib 138 extends in cantilever fashion from the inner surface 135 into the rectangular aperture 136. The rib 138 facilitates a secure fit with the radial teeth 102 of the laminate core 86, despite dimensional variations of the laminate core 86. As shown in FIG. 4, the flared portion 126 of the winding hub 114 closely matches the profile of the radial teeth 102 of the laminations 94, thereby substantially improving slot fill around the laminate core 86 (FIG. 4) and lowering winding resistance.

Referring to FIG. 6, each bobbin 106 includes a pair of bobbin terminals 142 coupled to the outer flange 122. The bobbin terminals 142 are electrically conductive members that may be inserted into the bobbin body 110 during an injection molding process. The bobbin terminals 142 may be coated with tin in order to facilitate soldering.

Referring to FIG. 8, a coil of wire 146, forming a stator winding, is wrapped around each bobbin 106, with wire ends 148 connected to the bobbin terminals 142. Referring to FIG. 3, the bobbin terminals 142 of each bobbin 106 extend through a printed circuit board assembly (PCBA) 150. The PCBA 150 connects the bobbin terminals 142, and thereby the windings, to power electronics coupled to the PCBA 150. The bobbin terminals 142 of all four bobbins 106 may be connected in series on the PCBA 150.

Referring to FIG. 3, the rotor assembly 18 includes a shaft 154 and a rotor 158 fixedly coupled to the shaft 154 for rotation with the shaft 154 relative to the stator assembly 14 about the shaft axis 38. The shaft 154 has a load end 160, for receiving a load to be driven, a case end 162, and an intermediate portion 163 between the load end 160 and the case end 162. The rotor 158 may include, for example, a plurality of permanent magnets.

The rotor assembly 18, more specifically the shaft 154, is rotatably coupled to the housing cover 22 with a cover bearing assembly 164 and rotatably coupled to the housing case 26 with a case bearing assembly 166. The cover bearing assembly 164 rotatably supports the intermediate portion 163 of the shaft 154, while case bearing assembly 166 rotatably supports the case end 162 of the shaft 154. The cover bearing assembly 164 and case bearing assembly 166 are substantially similar in most respects, with each bearing assembly 164 and 166 seated within the respective bearing seats 58 and 62 of the housing cover 22 and housing case 26.

FIG. 9 is an exploded view of the case bearing assembly 166. The case bearing assembly 166 includes a thrust plate 170, a felt pad 174, a sleeve bearing 178, and a bearing spring 182. The thrust plate 170 is a substantially planar, disk like member. Referring to FIG. 11, the sleeve bearing 178 includes a substantially cylindrical body with an outer surface 186 having tapered end portions 190. The sleeve bearing 178 defines a shaft aperture 194. The felt pad 174 is a washer like member with pad aperture 198 sized to receive the outer surface 186 of the sleeve bearing 178. The felt pad 174 may be formed, for example, of a wool or synthetic felt. A lubricant may be applied to the felt pad 174 to lubricate the sleeve bearing.

Referring to FIG. 10, the bearing spring 182 includes a unitarily formed body having a substantially planar base wall 202, and a substantially planar support wall 206. An oblique connecting wall 210 connects the base wall 202 and the support wall 206. An oblique outer wall extends 214 circumferentially about the support wall 206. Eight talon members 218 are coupled to the base wall 202 and surround a bearing spring aperture 222 (FIG. 9). The talon members 218 are bent away from the planar base wall 202 in a profile corresponding to the tapered end portions 190 of the sleeve bearing 178.

Referring to FIGS. 3 and 11, the thrust plate 170 is seated on the thrust support surface 66. The thrust plate 170 thus provides a bearing surface for the case end 162 of the rotor shaft 154. The felt pad 174 is seated on the pad support surface 74. The case end 166 of the rotor shaft 154 extends through the shaft aperture 194 of the sleeve bearing 178. The sleeve bearing 178 is seated upon the sleeve bearing support surface 70, and centered within the pad aperture 198. The bearing spring 182 is then seated such that the talon members 218 engage the sleeve bearing 178, the support wall 206 engages the spring support surface 78, and the oblique outer wall 214 resiliently engages the spring centering surface 82.

FIG. 12 illustrates a housing cover 226 according to another aspect of the invention. The housing cover 226 may be used with the motor assembly 10 in place of the housing cover 22 of FIGS. 1-3. The housing cover 226 includes a cover body 230 that may be formed, for example, of a thermoplastic. The cover body 230 defines a shaft aperture 234 disposed about a rotor shaft axis 238. Three cover assembly lugs 242 extend outwardly from edges of the cover body 230, for alignment with the case assembly lugs 46 of FIG. 2. Referring to FIG. 12, the housing cover 226 further includes three mounting lugs 246 disposed circumferentially about the shaft axis 238, approximately 120 degrees apart. Each mounting lug 246 defines a mounting aperture 250 for receiving, for example, a self-tapping mounting screw. The mounting lugs 246 are provided as an alternative mounting structure to the mounting lugs 50 of the housing case 36 (FIG. 2).

Thus, the invention provides, among other things, a new and useful electric motor. Various features and advantages of the invention are set forth in the following claims.

Claims

1. A bobbin for supporting a winding on electric motor stator laminations, the bobbin comprising:

a first flange member;

a second flange member substantially parallel to the first flange member;

a winding hub including an inner hub portion coupled to the first flange member and a flared portion connecting the inner hub portion to the second flange member such that a winding span defined between the first flange member and the flared portion tapers from the second flange member to the inner hub portion, an inner surface of the winding hub defining a bobbin aperture for receiving stator laminations of the motor; and

a rib member coupled to the inner surface and extending into the aperture for engaging the laminations.

2. The bobbin of claim 1, wherein the aperture has a polygonal profile.

3. The bobbin of claim 2, wherein the aperture has a rectangular profile.

4. The bobbin of claim 1, wherein the aperture is configured to receive a radial tooth of a stator lamination.

5. The bobbin of claim 4, wherein the flared portion is configured to substantially conform to a profile of the stator lamination.

6. The bobbin of claim 1, further comprising an electrically conductive terminal for coupling the bobbin to a printed circuit board (PCB).

7. The bobbin of claim 4, wherein the terminal extends from an edge portion of the first flange.

8. The bobbin of claim 1, wherein the rib extends from the inner surface in cantilever fashion.