Stator for a brushless D.C. motor

Abstract: A non-brush D.C. motor with a new improved stator comprises a stator base whose two side discs (3,4) have notches (28) and feet (22,23) so that the polar plates can engage with. By expanding the thinner lips of metal cylinder, the upper and lower polar plates can be fixed firmly with stator base. The central shaft post of housing base can pass through the inner perimeter of metal cylinder.

Description: BACKGROUND OF THE INVENTION This invention relates to a brushless D.C. motor with a new improved stator. According to the former application case of the U.S. Patent No. 4,987,331, a brushless D.C. motor with an improved stator is constituted by a base made of plastics having sides, a coil winding around the base, two magnetic polar plates each forming a pair of magnetic poles fixed at both sides of the base, and a circuit board connected at one side of the base. The advantages of that invention are easy to manufacture, no environmental pollution caused by using varnish, low installation cost, and the low rate of defective products. SUMMARY OF THE INVENTION The purpose of this invention is again to improve the stator so that the assembly work will be easier, and the thrust and repulsion of the motor will increase to start easily. This purpose is achieved with a stator of a brushless D.C. motor which is defined by the features indicated in claim 1. BRIEF DESCRIPTION OF THE DRAWINGS This invention will now be described in detail with reference to the accompanying drawings wherein; Figure 1 is a solid exploded perspective of the brushless D.C. motor in accordance with this invention; Figure 2 is a bottom view of the stator base combined with magnetic polar plates; Figure 3 is a cross-sectional view taken along line 3-3 of Figure 2; Figure 4 is a side view of the stator base combined with magnetic polar plates and a circuit board; Figure 5 is the first example of the stator base combined with upper and lower magnetic polar plates; Figure 6 is the second example of the stator base combined with upper and lower magnetic polar plates; and Figure 7 is a top view of the brushless D.C. motor in accordance with this invention. DETAILED DESCRIPTION OF THE INVENTION First, referring to Fig. 1, a brushless D.C. motor in accordance with this invention comprises a housing base 1 with a central shaft post 11. The outer perimeter of the central shaft post 11 is to provide the constituting elements of the stator to combine. The inner perimeter of the central shaft post 11 has a bearing, inside which the shaft 71 of rotor 7 is inserted and rotated. The stator comprises a stator base 2, upper polar plate 3, lower polar plate 4, a metal cylinder 5, and a circuit board 6. The stator base 2 is a winding wheel made of plastics with two side discs. The central perimeter 21 of the stator base 2 is wound by the coil. Two side discs have two sets of feet 22, 23 symmetrically protruding out, and notches 28 which have the same shape as upper and lower polar plates 3, 4. The notches 28 are engaged with polar plates 3, 4. The polar plates 3, 4 are firmly fixed with the stator base 2 by means of feet 22, 23 passing through the holes 31, 41 of the polar plates 3, 4. The central hole 24 located at the center of stator base 2 is provided with a metal cylinder 5 inserted therein. The stator base has feet 25 which engage the holes 62 of the circuit board 6, and other feet 26 which support the surface of the circuit board 6 to let them keep suitable spacing as shown in Fig. 4. The stator base 2 has a hole 27 to settle the IC 61 firmly. The upper polar plate 3 and lower polar plate 4 engage the notches 28 of respective discs of stator base 2. In the holes 31, 41 of polar plates 3, 4 are inserted the feet 22, 23 of the stator base 2. In the holes 35, 45 of polar plates 3, 4 are inserted the thinner lips 51 of metal cylinder 5. The thinner lips 51 are expanded by punching method, as shown in Fig. 3, to fix polar plates 3, 4 and stator base 2 firmly. Each polar plate consists of at least one plate. The recesses 32, 42 are at the respective pole of polar plates 3, 4. The air gap between the recesses 32, 42 and the permanent magnet 72 of rotor 7 is to increase the starting torque for rotor 7 starting easier by the different magnetic flux distribution at the magnetic poles. The rear part 33 of one polar plate 3 and the front part 44 of the other polar plate 4 are spaced in circumferential direction by a distance which is bigger than the distance by which the front part 34 of said one polar plate 3 is spaced in circumferential direction from the rear part 43 of said other polar plate 4 , as shown in Fig. 5, for better characteristics of magnetic induction. The polar plates can be designed as another form like upper polar plates 3' and lower polar plates 4' as shown in Figs. 1, 6. Each pole face of polar plates 3' and 4' has a respective recess 32' or 42' so that the different air gap between pole faces and the permanent magnet 72 of rotor 7 results in different reluctance. The rotor 7 will increase the starting torque for starting easily because of the non-uniform magnetic flux in the magnetic poles. The polar plates 3, 4 or the polar plates 3', 4' are bipolar. The outer perimeter of the metal cylinder consists of one wider central part and two thinner lips 51. The central part of the metal cylinder is to combine with stator base 2. The two thinner lips 51 fix the polar plates 3, 4. By punching and expanding, two thinner lips 51 will combine polar plates 3, 4 with stator base 2 and metal cylinder 5. The inner perimeter 52 of the metal cylinder 5 is to provide the central shaft post 11 of housing base 1 to pass through. Circuit board 6 will be fixed firmly by setting the feet 25 of stator base 2 in the holes 62. The electronic elements inside the circuit board 6 are used as driving circuit for starting the motor. The IC 61 of circuit board 6 is firmly fixed in the groove 27 of stator base 2. The brushless D.C. motor in accordance with this invention is more compact than the former one. The assembly work will be easier and no varnish is used in manufacturing process to pollute the environment. Moreover, less electric leakage and better insulation effect in manufacturing will reduce the defect rate of products.

Claims: A brushless D.C. motor, including a housing base (1), a stator (2, 3, 4, 5) having a circuit board (6), and a rotor (7) having a shaft (71), said stator further comrising: a stator base (2) made of plastics and serving as a coil winding wheel having a center hole (24) and two side discs on which there are formed feet (22, 23) and notches (28); two polar plates (3, 4; 3', 4') having substantially the same shape as said notches (28) and having holes (31, 41; 31', 41') to engage with said feet (22, 23); and a metal cylinder (5) which is insertable in said center hole (24) of said stator base (2), said stator being characterised in that each of said two polar plates (3, 4; 3', 4') has two diametrically opposed recesses (32, 42; 32', 42') on its circumferential face to form gaps with determined widths between the permanent magnet of said rotor (7) and said circumferential face; said housing base (1) comprises a central shaft post (11) on the outer peripheral surface of which the constituting elements of said stator are combined and on the inner peripheral surface of which a bearing is formed for rotatively accommodating said shaft (71) of said rotor (7); said metal cylinder (5) has a wider central part and two thinner lips (51) on both of its ends and is able to accommodate said shaft post (11) of said housing base (1) by setting the inner perimeter of said metal cylinder (5) at the outer perimeter of said central shaft post (11); and said polar plates (3, 4; 3', 4') are of the bipolar type and are fixed on said respective thinner lips (51) of said metal cylinder (5) in an angular position in which their polar axes are oriented to each other at an angle different from a right angle such that in an axial projective view the rear part (33; 33') of one polar plate (3; 3') and the front part (44; 44') of the other polar plate (4; 4') are spaced in circumferential direction by a distance which is bigger than the distance by which the front part (34; 34') of said one polar plate (3; 3') is spaced in circumferential direction from the rear part (43; 43') of said other polar plate (4; 4'). The brushless D.C. motor according to claim 1, wherein one side of said stator base (2) has a groove (27) to firmly fix an IC. The brushless D.C. motor according to claim 1, wherein said wider central part of said metal cylinder (5) is combined with said stator base (2) and said two thinner lips (51) serve to fix said upper and lower polar plates (3, 4; 3', 4') by punching and expanding said thinner lips (51) so that said stator base (2) together with the other constituting elements (3, 4; 3', 4'; 6) are fixed on said shaft post (11) of said housing base (1).

Inventors: HORNG ALEX, HORNG, ALEX
Applicants: HORNG ALEX, HORNG, ALEX
Application year: 1991
Main classification: H02K21
IPC codes: H02K1, H02K29, H02K21