Patent ID: 12212207

DETAILED DESCRIPTION

Hereafter, one or more implementations of the present disclosure are described in detail with reference to the accompanying drawings to describe the present disclosure in more detail. Like reference numerals indicate the same components throughout the detailed description.

FIG.1is a perspective view showing an example of a stator1.

In some implementations, a concentrated type motor can include the stator1, and the stator1can include a split-core assembly10.

The split-core assembly10can include a plurality of parts. For example, the split-core assemblies10can be circumferentially arranged around a central axis S of the stator1. That is, a plurality of split-core assemblies10can be circumferentially arranged around the central axis S. The stator1shown inFIG.1can be formed by combining the plurality of split-core assemblies10.

In some examples, a motor including the stator1can be a 3-phase motor, and the number of the split-core assemblies10forming one stator1can be a multiple of 3. For example, as shown inFIG.1, the number of the split-core assemblies10of one stator1can be 24.

In the present disclosure, the direction that is parallel with the direction of the central axis S of the stator1is defined as an up-down direction. The circumferential direction in the present disclosure refers to a circumferential direction around the central axis S, and the radial direction refers to the radial direction from the central axis S unless stated otherwise.

In some implementations, the plurality of split-core assemblies10can be arranged such that both ends are in close contact with each other in the circumferential direction. The split-core assemblies10can be coupled to each other by their own parts, or can be coupled to each other through other parts. As for the former, for example, the split-core assemblies10can be fitted or locked to each other, and as for the latter, for example, the split-core assemblies10can be inserted and coupled to each other in the housing of a motor.

The stator1to which the split-core assemblies10are coupled can have a ring shape. In some examples, where the stator1is included in a concentrated type motor, a rotor can be positioned in the central space B of the stator1and can be rotated about the central axis S.

FIG.2is a perspective view showing the split-core assembly10shown inFIG.1,FIG.3is a perspective view separately showing a split core100, a bobbin200, and a terminal holder400of the split-core assembly shown inFIG.2,FIG.4is an exploded perspective view showing the stator1shown inFIG.1and conductive plates20,30,40, and50coupled to the stator1,FIG.5is a partial enlarged plan view showing the state in which the stator a and the conductive plates20,30,40, and50are coupled, andFIG.6is a perspective cross-sectional view taken along line A-A′ ofFIG.5.

The split-core assembly10can include a split core100, a bobbin200, a coil300, and a terminal holder400.

The split core100can be made of conductive metal. The split core100can be formed by stacking several metal plates (core plates) in the up-down direction, in which the metal plates can have the same shape and size.

The split core100can have a yoke110and a tooth120extending close to the central axis S from the yoke110.

The yoke110is the portion that is relatively far from the central axis S and the tooth120is the portion that is relatively close to the central axis S. The yoke110has a circumferential with, as compared with the tooth120.

The inner surface121of the tooth120can be a curved surface and faces the central axis S of the stator1.

When split-core assemblies10are coupled to each other, any one split core100and the other split core100can be in close contact with each other, and in this case, the yokes110of the split cores100can be in close contact with each other.

In order to stably bring the split cores100in close contact with each other and in order to stably couple the split cores100, a protrusion111that circumferentially protrudes can be formed on any one side of the yoke110and a concave groove112can be formed on the other side so that the protrusion111is inserted therein. The protrusion111and the groove112can be fitted to each other. That is, the protrusion111and the groove112can be located at opposite sides in the circumferential direction and can have corresponding shapes and sizes (seeFIG.3).

The bobbin200can be made of an insulator and can be coupled to the outer side of the split core100. The bobbin200can be made of plastic. The bobbin200can surround at least a portion of the tooth120.

The bobbin200is provided for insulation between the split core100and a coil300when the coil300is wound around the split core100. The bobbin200is positioned between the split core100and the coil300and surrounds the tooth120of the split core100. The bobbin200can be formed in a tube shape, and in this case, the axis thereof can be defined in the radial direction of the stator1.

In some implementations, the bobbin200can have a winding portion210, an outer flange220, and an inner flange230.

The coil300can be wound on the outer surface of the winding portion210.

The winding portion210can be formed in a tube shape, and in this case, the axis of the winding portion210can face the radial direction of the stator1, and the cross-section of the winding portion210can be a rectangle.

The outer flange220can be integrated with the winding portion210and formed such that the diameter increases at a position that is farther from the central axis S than the winding portion210. That is, the outer flange220is formed such that the edge opens outward at the winding portion210. The outer flange220can form the outer end of the bobbin200in the radial direction of the stator1. The outer flange220can form the boundary of the region in which the coil300is wound when the coil300is wound on the winding portion210.

In the split-core assemblies10and the stator1, the outer flange220can be integrated with the terminal holder400. That is, the terminal holder400can be integrated with the bobbin200.

The inner flange230can be integrated with the winding portion210and formed such that the diameter increases at a position that is closer to the central axis S than the winding portion210. That is, the inner flange230is formed such that the edge opens outward at the winding portion210. The inner flange230can form an end of the bobbin200at the opposite side to the outer flange220. That is, the inner flange230can form the inner end of the bobbin200in the radial direction of the stator1. The inner flange230can form the boundary of the region in which the coil300is wound when the coil300is wound on the winding portion210.

A first groove221and a second groove222can be formed at the upper portion of the outer flange220.

The first groove221is formed to be concave downward from the upper end of the outer flange220and the outer flange220is radially pierced by the first groove221. An end310of the coil300to which A connection portion21of an N-phase conductive plate20of the conductive plates is coupled is inserted in the first groove221.

The second groove222is spaced apart from the first groove221and is formed to be concave downward from the upper end of the outer flange220, and the outer flange220is pierced by the second groove222. An end320of the coil300that is coupled to one of a connection portion31of a U-phase conductive plate30, a connection portion42of a V-phase conductive plate40, and a connection portion51of a W-phase conductive plate50is inserted in the second groove222.

In some implementations, the bobbin200can include a first bobbin200aand a second bobbin200b.

The first bobbin200ais a part coupled to the upper portion of the tooth120and the second bobbin200bis a part coupled to the lower portion of the tooth120. The second bobbin200bis coupled to the first bobbin200a, thereby surrounding the tooth120.

The first bobbin200ahas a first winding portion210a, a first outer flange220a, and a first inner flange230a.

The first winding portion210a, which is the portion on which the coil300is wound, forms the upper portion of the winding portion210.

The first outer flange220ais formed such that the diameter increases at a position farther from the central axis S than the first winding portion210a, and forms the upper portion of the outer flange220.

In some implementations, when the bobbin200is divided into the first bobbin200aand the second bobbin200b, the first groove221and the second groove222can be formed at the first outer flange220a.

The first inner flange230ais formed such that the diameter increases at a position closer to the central axis S than the first winding portion210a, and forms the upper portion of the inner flange230.

The second bobbin200bcan have a second winding portion210b, a second outer flange220b, and a second inner flange230b.

The second winding portion210b, which is the portion on which the coil300is wound, forms the lower portion of the winding portion210.

The second outer flange220bis formed such that the diameter increases at a position farther from the central axis S than the second winding portion210b, and forms the lower portion of the outer flange220.

The second inner flange230bis formed such that the diameter increases at a position closer to the central axis S than the second winding portion210b, and forms the lower portion of the inner flange230.

The lower portion of the first bobbin200aand the upper portion of the second bobbin200bcan be formed such that any one thereof is fitted in the other one. That is, the lower portion of the first bobbin200aand the upper portion of the second bobbin200bcan overlap each other. The portion of the first bobbin200athat overlaps the second bobbin200bis a first overlap portion240, and the portion of the second bobbin200bthat overlaps the first bobbin200ais a second overlap portion250. The first overlap portion240can be formed at the lower ends of the first winding portion210a, the first outer flange220a, and the first inner flange230a, and the second overlap portion250can be formed at the upper ends of the second winding portion210b, the second outer flange220b, and the second inner flange230b.

Accordingly, when the first bobbin200aand the second bobbin200bare coupled, relative movement in the circumferential direction and the radial direction between the first bobbin200aand the second bobbin200bis restricted, whereby they can be stably coupled.

The coil300is made of conductive metal and can be made of copper, and is repeatedly wound on the outer surface of the winding portion210of the bobbin200. A first end310that is any one end of the coil300can be fitted in the first groove221of the outer flange220and positioned toward the terminal holder400. Further, a second end320that is the other end of the coil300can be fitted in the second groove222of the outer flange220and positioned toward the terminal holder400.

In some implementations, the terminal holder400can be made of an insulator. In some examples, the terminal holder400can be integrated with the bobbin200. When the bobbin200is divided into the first bobbin200aand the second bobbin200b, the terminal holder400can be integrated with the first bobbin200a. In some examples, the terminal holder400can be at least partially disposed on the yoke110.

A plurality of insertion grooves401,402,403, and404in which the plurality of conductive plates20,30,40, and50electrically connected to the coil300are inserted, respectively, can be sequentially formed at the terminal holder400.

A motor including the split-core assemblies10and the stator1can be a 3-phase motor, and in this case, the conductive plates20,30,40, and50and the coil300can be connected to make Y-wiring.

The conductive plates20,30,40, and50coupled to the stator1can be four conductive plates. The N-phase conductive plate20that forms a neutral point, and the U-phase conductive plate30, V-phase conductive plate40, and W-phase conductive plate50that form 3 phases each can be connected to the terminal holder400. The four conductive plates20,30,40, and50can be coaxially arranged (around the central axis S).

Four insertion grooves401,402,403, and404can be formed at the terminal holder400such that the four conductive plates20,30,40, and50are inserted therein, respectively. The insertion grooves401,402,403, and404are narrow and long grooves and are elongated in the circumferential direction of the stator1.

The terminal holder400has a plurality of partition walls441,442,443,444, and445spaced apart from each other to form the insertion grooves401,402,403, and404.

In some implementations, the partition walls441,442,443,444, and445can be radially spaced apart from each other. That is, the partition walls441,442,443,444, and445can be spaced apart from each other in a direction perpendicular to the central axis S. In some implementations, the partition walls can be spaced apart from each other in a direction not perpendicular to the central axis S or can be spaced apart from each other in a direction inclined a predetermined angle from the central axis S.

It is assumed in the following description that the partition walls441,442,443,444, and445are spaced apart from each other in a radial direction of the central axis S.

The terminal holder400has a bottom plate430and a plurality of partition walls441,442,443,444, and445such that the insertion grooves401,402,403, and404can be formed.

The bottom plate430connects the lower ends of the plurality of partition walls441,442,443,444, and445to each other. The bottom plate430can form the innermost surfaces of the insertion grooves401,402,403, and404, and the top of the bottom plate430can be the bottoms401a,402a,403a, and404aof the insertion grooves401,402,403, and404.

The bottom plate430can form a portion of a fan shape in a plane. That is, the bottom plate430can be formed such that the circumferential width increases as it goes away from the central axis S, and both edges of the bottom plate430can be arranged in the radial direction of the stator1.

The terminal holder400has five partition walls441,442,443,444, and445to form the four insertion grooves401,402,403, and404.

The four insertion grooves401,402,403, and404can be formed in the radial direction of the stator1, can form a portion of a coaxial circle, and can be spaced apart from each other with the same intervals by the partition walls441,442,443,444, and445.

The insertion grooves401,402,403, and404of the terminal holder400are open upward, and the conductive plates20,30,40, and50are inserted downward in the insertion grooves401,402,403, and404.

The up-down heights of the partition walls441,442,443,444, and445(the up-down heights of the insertion grooves401,402,403, and404) are larger than the up-down heights of the conductive plates20,30,40, and50.

The partition walls441,442,443,444, and445can be formed such that the widths (circumferential lengths) thereof are sequentially increased as they go away from the central axis S.

The partition walls441,442,443,444, and445can be formed circumferentially throughout the entire region of the bottom plate430. That is, the circumferential lengths of the partition walls441,442,443,444, and445can be the same as the circumferential length of the bottom plate430at the positions where the partition walls441,442,443,444, and445are connected.

The partition walls can be classified into middle partition walls441,442, and443, an outer partition wall444, and an inner partition wall445. That is, the terminal holder400can have middle partition walls441,442, and443, an outer partition wall444, and an inner partition wall445.

The middle partition walls441,442, and443form the boundaries of the plurality of insertion grooves401,402,403, and404, and can be provided as a plurality of pieces. When four insertion grooves401,402,403, and404are provided, three middle partition walls441,442, and443are provided. The middle partition walls441,442, and443can all have the same height.

The outer partition wall444can be farther from the ends310and320of the coil300than the middle partition walls441,442, and443, and can be spaced apart from the middle partition walls441,442, and443.

The outer partition wall444can be positioned outside the middle partition wall443(far from the central axis S) which is farthest from the central axis S in the radial direction. The height of the outer partition wall444can be larger than the height of the middle partition walls441,442, and443.

The inner partition wall445can be closer to the ends310and320of the coil300than the middle partition walls441,442, and443, and can be spaced apart from the middle partition walls441,442, and443.

The inner partition wall445can be positioned inside the middle partition wall441(close to the central axis S) which is closest to the central axis S in the radial direction. The height of the inner partition wall445can be the same as the height of the middle partition walls441,442, and443.

In some implementations, 3-phase terminal grooves441a,442a,443a, and445acan be formed at the middle partition walls441,442, and443and the inner partition wall445. The 3-phase terminal grooves441a,442a,443a, and445acan be formed downward from the upper ends of the middle partition walls441,442, and443and the inner partition wall445. The upper portions of the middle partition walls441,442, and443and the inner partition wall445are radially pierced by the 3-phase terminal grooves441a,442a,443a, and445a.

The length (height) from the lower ends of the 3-phase terminal grooves441a,442a,443a, and445ato the top (the bottoms401a,402a,403a, and404a) of the bottom plate430can be larger than or the same as the up-down length (height) of the 3-phase terminal grooves441a,442a,443a, and445a.

The 3-phase terminal grooves441a,442a,443a, and445acan be arranged straight at the terminal holder400.

The connection portion31of the U-phase conductive plate30, the connection portion41of the V-phase conductive plate40, and the connection portion51of the W-phase conductive plate50are individually fitted in the 3-phase terminal grooves441a,442a,443a, and445a, respectively.

In some implementations, a neutral terminal groove445bcan be defined at the inner partition wall445. For example, the neutral terminal groove445bcan be recessed downward from the upper end of the inner partition wall445. The upper portion of the inner partition wall445is radially pierced by the neutral terminal groove445b.

The length (height) from the lower end of the neutral terminal groove445bto the top (the bottoms401a,402a,403a, and404a) of the bottom plate430can be larger than or the same as the up-down length (height) of the neutral terminal groove445b.

The connection portion21of the N-phase conductive plate20is fitted in the neutral terminal groove445b.

In some implementations, when the inner partition wall445, the middle partition walls441,442, and443, and the outer partition wall444are formed in the radial direction of the stator1, the upper end of the outer flange220can be higher than the upper ends of the middle partition walls441,442, and443and the inner partition wall445, and the gap between the outer flange220and the inner partition wall445can be larger than the gaps between the partition walls441,442,443,444, and445.

In some implementations, the ends310and320of the coil300and the connection portions21,31,42, and51of the conductive plates20,30,40, and50can be easily coupled in a space405between the outer flange220and the inner partition wall445. In some examples, the ends310and320of the coil300and the connection portions21,31,42, and51of the conductive plates20,30,40, and50can be coupled without being exposed over the upper ends of the bobbin200and the terminal holder400. In some examples, the connection portions21,31,42, and51can include a strip or bar of a conductor that includes an end hook connected to the end320of the coil300.

FIG.7Ais an enlarged perspective view showing a portion of the bobbin200and the terminal holder400shown inFIG.3,FIG.7Bis a perspective view showing the portion of the bobbin200and the terminal holder400shown inFIG.7Ain another direction, andFIG.8is a plan view showing the bobbin200and the terminal holder400shown inFIG.3.

In some implementations, insulating protrusions411,412,413, and414can be integrally formed at the terminal holder400. In some implementations, insulating grooves421,422,423, and424can be formed at the terminal holder400.

The insulating protrusions411,412,413, and414can protrude toward a certain surface crossing the central axis S, at the terminal holder400.

The insulating protrusions411,412,413, and414can protrude in the circumferential direction of the terminal holder400.

Accordingly, in some implementations, when two terminal holders400are coupled to each other, the insulating protrusions411,412,413, and414of any one terminal holder400can overlap the other terminal holder400, and it can be possible to shield between the split core100and the conductive plates20,30,40, and50.

The insulating protrusions411,412,413, and414can protrude in the circumferential direction of the stator1from an end of the bottom plate430. The insulating protrusions411,412,413, and414can protrude in the circumferential direction of the stator1from an end of any one or more of the partition walls441,442,443,444, and445. Since the insulating protrusions411,412,413, and414protrude from the bottom plate430and any one of the partition walls441,442,443,444, and445, the insulating protrusions411,412,413, and414can have aorshape, e.g., an L shape. That is, the cross-section of the insulating protrusions411,412,413, and414can have aorshape, e.g., an L shape.

The insulating protrusions411,412,413, and414can be formed at the insertion grooves401,402,403, and404, respectively. In this case, the insulating protrusions411,412,413, and414can be formed radially throughout the insertion grooves401,402,403, and404and can be formed throughout the insertion grooves401,402,403, and404in the up-down direction.

Since the insulating protrusions411,412,413, and414are formed at the insertion grooves401,402,403, and404, respectively, when four insertion grooves401,402,403, and404are provided, four insulating protrusions411,412,413, and414can be provided. When a plurality of insulating protrusions411,412,413, and414are provided at one terminal holder400, the insulating protrusions411,412,413, and414can be formed in the same shape.

The thickness of the insulating protrusions411,412,413, and414can be smaller than the thicknesses of the bottom plate430and the partition walls441,442,443,444, and445. For example, the thickness of the insulating protrusions411,412,413, and414can be about ½ of the thicknesses of the bottom plate430and the partition walls.

The insulating grooves421,422,423, and424are formed opposite the insulating protrusions411,412,413, and414at the terminal holder400. That is, at the terminal holder400, the insulating grooves421,422,423, and424and the insulating protrusions411,412,413, and414are formed at both circumferential ends.

The insulating grooves421,422,423, and424can be concave grooves or stepped grooves formed at an end of the bottom plate430.

In some implementations, when two terminal holders400are coupled to each other, the insulating protrusions411,412,413, and414of any one terminal holder400can be seated in the insulating grooves421,422,423, and424of the other terminal holder400.

The insulating grooves421,422,423, and424can be formed to be concave and can be stepped in the circumferential direction of the stator1at a circumferential end of the partition walls. Since the insulating grooves421,422,423, and424are formed at the bottom plate430and any one of the partition walls441,442,443,444, and445, the insulating grooves421,422,423, and424can make aorshape, e.g., an L shape. The insulating grooves421,422,423, and424can have a shape and a size that correspond to those of the insulating protrusions411,412,413, and414.

The insulating grooves421,422,423, and424may be formed at the insertion grooves401,402,403, and404, respectively. In this case, the insulating grooves421,422,423, and424may be formed radially throughout the insertion grooves401,402,403, and404and can be formed throughout the insertion grooves401,402,403, and404in the up-down direction.

Since the insulating grooves421,422,423, and424are formed at the insertion grooves401,402,403, and404, respectively, when four insertion grooves401,402,403, and404are provided, four insulating grooves421,422,423, and424are provided. When a plurality of insulating grooves421,422,423, and424are provided at one terminal holder400, the insulating grooves421,422,423, and424may be formed in the same shape.

As described above, the terminal holder400has the bottom plate430, the insulating protrusions411,412,413, and414, and the insulating grooves421,422,423, and424. Further, when two split-core assemblies10are coupled to each other, the insulating protrusions411,412,413, and414of any one terminal holder400are inserted or seated in the insulating grooves421,422,423, and424of the other terminal holder400. Accordingly, it is possible to effectively and stably overlap the terminal holders400and shield between the split core100and the conductive plates20,30,40, and50.

FIG.9is a plan view showing an example of a bobbin200and a terminal holder400.

In some implementations, the protruding degrees (e.g., circumferential lengths) of the insulating protrusions411,412,413, and414can be increased as they go away from the central axis S.

When a plurality of insulating protrusions411,412,413, and414are formed at one terminal holder400, the insulating protrusions411,412,413, and414that are relatively far from the central axis S can further protrude than the insulating protrusions411,412,413, and414that are relatively close to the central axis S.

In this case, the insulating grooves421,422,423, and424can also formed to corresponding to the protruding degrees of the insulating protrusions411,412,413, and414, respectively.

When a plurality of split-core assemblies10are circumferentially coupled to each other, the gap between the terminal holders400can be increased as it goes away from the central axis S. In some examples, the protruding degrees of the insulating protrusions411,412,413, and414are increased as they go away from the central axis S, to thereby effectively reduce or prevent a gap between the terminal holders400.

Although a specific implementation of the present disclosure was described above with reference to drawings, the present disclosure is not limited thereto and it should be understood that the present disclosure can be changed and modified by those skilled in the art in various ways through more detailed implementations without departing from the spirit and scope of the present disclosure. Accordingly, the range of the present disclosure should be defined not by the implementations described above, but by the spirit described in claims.

In the split-core assembly and a stator including the split-core assembly, insulating protrusions are formed at a terminal holder, and when two split-core assemblies are coupled to each other, the insulating protrusions of any one terminal holder overlap the other terminal holder. Accordingly, it can be possible to prevent or reduce a gap between the split-core assemblies, and the present disclosure has sufficient industrial applicability because a portion between the split core and the conductive plates is shielded.