Patent ID: 12191719

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present disclosure will now be described more specifically with reference to the following embodiments. It is to be noted that the following descriptions of preferred embodiments of this disclosure are presented herein for purpose of illustration and description only. It is not intended to be exhaustive or to be limited to the precise form disclosed.

Please refer toFIGS.1and2.FIG.1is a schematic perspective view illustrating a motor10according to an embodiment of the present disclosure.FIG.2is a schematic exploded view of the motor10ofFIG.1. The motor10includes a stator1and a rotor9. The stator1includes a winding assembly2and a pillow3. The rotor9is sleeved on the winding assembly2, and the rotor9rotates along a central axis J. In other words, the rotor9is disposed circumferentially with respect to the central axis J.

In the figures of the present disclosure, the axial direction is assumed to be the direction in which the central axis J of the stator1extends. The direction parallel or substantially parallel to the central axis is referred to by the term “axial” or “axially”. With the central axis as the center, the directions away from the central axis are simply referred to as the term “radial” or “radially”, and the circumferential direction around the central axis is simply referred as the term “circumferential” or “circumferentially”.

Please refer toFIGS.3,4and5.FIG.3is a schematic perspective view illustrating a stator1of the motor10according to an embodiment of the present disclosure.FIG.4is a schematic exploded view of the stator3ofFIG.3.FIG.5is a schematic exploded view of the stator1ofFIG.3at another viewing angle. The stator1includes a winding assembly2and a pillow3. The pillow3includes a shaft tube30and a plate31. The shaft tube30is disposed on a side of the pillow3connected to the rotor9. The winding assembly2is disposed circumferentially on the shaft tube30. The plate31has an inner side310neighboring to the shaft tube30and a flange311disposed circumferentially on the inner side310. A heat dissipation member33is disposed on a side of the flange311of the plate31facing the shaft tube30. Substantially, the heat dissipation member33extends axially with respect to the flange311of the plate31and extends radially with respect to the shaft tube30. A first insertion hole3101is disposed on the inner side310of the plate31. A waterproof element4is at least partially disposed in the first insertion hole3101. The winding assembly2has a plurality of coils20, for example, the number of coils20is greater than 3 and is a multiple of 3, and a conductive element is extended out from each coil20and is connected to a first electrical connector7. The first electrical connector7penetrates through the waterproof element4and the first insertion hole3101. An end of the first electrical connector7is located at an opposite side of the plate31, which is opposite to the side where the shaft tube30is disposed. The conductive elements are extended out from the plurality of coils20respectively, and each conductive element is electrically connected to the corresponding first electrical connector7directly. Alternatively, the coils with the same phase are electrically connected to each other, and then connected to the first electrical connector7via the same conductive element.

The pillow3further includes a cylinder32disposed on the opposite side of the plate31relative to the shaft tube. The cylinder32is substantially a cylindrical structure extending axially, and the cylinder32forms a first space321. A first circuit board51is disposed in the first space321. A clamp510is disposed on the first circuit board51, and a first opening515is disposed at the center of the first circuit board51. The first electrical connector7extended from the coil20penetrates the plate31through the first insertion hole3101, and is contacted with the clamp510on the first circuit board51. Accordingly, the coil20is electrically connected to the first circuit board51through the first electrical connector7. The number of the first insertion hole3101is basically the same as that of the first electrical connector7. Furthermore, the number of the clamp510is also the same as that of the first electrical connector7. In addition, the cylinder32has waterproof joints322disposed thereon for external connections, and a flat region323concavely and inwardly formed thereon, as shown inFIG.5.

Generally, the entire pillow3is a metal structure. A first insulation plate53is disposed between the pillow3and the first circuit board51. An insertion body530is disposed on the first insulation board53and is corresponding to the first insertion hole3101. A second opening531is disposed at the center of the first insulation plate53. The insertion body530has a perforation aligned with the first insertion hole3101for allowing the first electrical connector7to penetrate therethrough.

Please continue referring toFIGS.4and5. A second circuit board52is further disposed in the first space321formed by the cylinder32. A second insulation board54is disposed between the first circuit board51and the second circuit board52. A side wall542is extended axially from the periphery of the second insulation plate54and forms a second space541. The second circuit board52is disposed in the second space541. The stator1further includes a cover34connected to the cylinder32. Consequently, the first space321is substantially an enclosed space for accommodating the first insulation board53, the first circuit board51, the second insulation board54and the second circuit board52.

In this embodiment, the second circuit board52has the same function as the circuit board of the conventional motor with electronic commutation components disposed thereon for driving the integrated circuit, and the first circuit board51has the same function as the wire binding plate of the conventional motor. Generally, the first circuit board51does not include open-loop and closed-loop control components and electronic commutation components for the motor.

FIG.6Ais a schematic exploded view illustrating the two circuit boards and the two insulation plates inFIG.5. Please refer to theFIGS.5and6A, the first opening515of the first circuit board51and the second opening531of the first insulation plate53are axially aligned with each other, so that a shaft (not shown) is allowed to penetrate through the first opening515and the second opening531. A second electrical connector516is disposed on the first circuit board51, and the second electrical connector516penetrates through a second insertion hole543disposed on the second insulation board54. Therefore, the first circuit board51and the second circuit board52are electrically connected to each other through the second electrical connector516.

InFIG.6A, the type of the second electrical connector516is a metal pin, but not limited thereto.

FIG.6Bis a schematic enlarged view of square A ofFIG.6A. Please refer toFIGS.6A and6B, the clamp510disposed on the first circuit board51is a conductive element including a clamping part511and an engaging part512. The engaging part512penetrates through an engaging hole513of the first circuit board51correspondingly, and the clamp510is fixed on the first circuit board51and is electrically connected to the first circuit board51. The clamping part511has two metal components, which can clamp the first electrical connector7shown inFIG.5. The first circuit board51further includes a penetrating hole514corresponding to the clamping part511. When the clamping part511clamps the first electrical connector7, the penetrating hole514can be selectively provided for the first electrical connector7to penetrate therethrough.

In the embodiment shown inFIGS.6A and6B, the clamp510is disposed on a side of the first circuit board510neighboring to the second circuit board52, which is the side away from the shaft tube30, but not limit thereto.

Please continue referring toFIG.6C.FIG.6Cis a schematic view illustrating the clamp510ofFIG.6Baccording to another embodiment of the present disclosure. The clamp510of theFIG.6Cis disposed on a side of the first circuit board51neighboring to the first insulation board53, which is the side facing the shaft tube30. In short, the clamp510serves as a connector electrically connected to the first circuit board51, and the clamp510is configured to electrically connect the first electrical connector7to the first circuit board51.

FIG.7Ais a schematic perspective view illustrating a waterproof element4according to an embodiment of the present disclosure.FIG.7Bis a schematic perspective view illustrating the waterproof element4ofFIG.7Aat another viewing angle. Please refer toFIGS.7A and7B, the waterproof element4is a waterproof structure at least partially disposed in the first insertion hole3101, and is configured for allowing the first electrical connector7to penetrate therethrough. The waterproof element4includes an airtight part41, a positioning part42and an extension part43. Preferably but not exclusively, the waterproof element4is made of rubber or plastic. When the waterproof element4is disposed, the extension part43is inserted into the first insertion hole3101, and the airtight part41and the positioning part42are disposed on the inner side310of the plate31neighboring to the shaft tube30.

Please refer toFIG.8.FIG.8is a schematic cross-sectional view showing the motor10inFIG.1. The winding assembly2is disposed circumferentially on the pillow3around the shaft tube30. The rotor9includes a shaft91and a hub92connected to the shaft91. The shaft91is disposed in the shaft tube30, and a magnet8is disposed inside the hub92corresponding to the winding assembly2. The shaft91drives the rotor9to rotate along the central axis J. The motor10of the present disclosure is an external-rotor motor in which the rotor9is circumferentially disposed at the outside of the winding assembly2of the stator1, so as to form a rotation structure with the rotor9located at the outer side and the stator1located at the inner side.

FIG.9is a schematic enlarged view of square B ofFIG.8. Please continue referring toFIGS.8and9, the first electrical connector7is extended out from the coil20of the winding assembly2, and the first electrical connector7penetrates through the first insertion hole3101at the inner side of the pillow3and is electrically connected to the first circuit board51in the first space321. In the embodiment shown inFIG.9, a conductive element21is extended from the coil20, and the conductive element21is electrically connected to the first electrical connector7and penetrates through the waterproof element4. In this embodiment, the conductive element21is generally a flexible wire. In terms of manufacturing, the conductive element21is connected to the rigid metal part of the first electrical connector7first, and then penetrates through the waterproof element4.

Please continue referring toFIGS.7A,7B and9. As mentioned above, when the waterproof element4is partially disposed in the first insertion hole3101as a waterproof structure, the extension part43is inserted into the first insertion hole3101, and the airtight part41and the positioning part42are disposed on a side of the plate31neighboring to the shaft tube30(i.e., the side neighboring to the coil20). A protrusion3102is disposed on a side of the inner side310of the plate31neighboring to the shaft tube30, and the protrusion3102is adjacent to the first insertion hole3101. Therefore, the positioning part42of the waterproof element4is engaged with the protrusion3102to fix the position of the waterproof element4. After the positioning part42is engaged with the protrusion3102, the airtight part41is located at a radial outer side of the conductive element21and has an insulation function. The first insulation board53disposed between the first circuit board51and the plate31has the insertion body530. The insertion body530is disposed corresponding to the first insertion hole3101, and the insertion body530further extends to the position between the plate31and the waterproof element4so as to fix the relative position of the first electrical connector7and the first circuit board51. The second insulation plate54is configured as an insulator between the first circuit board51and the second circuit board52. The first insulation board53further includes a guiding part532as a protrusion toward to the first circuit board51. The guiding part532is disposed corresponding to the insertion body530and the first insertion hole3101of the plate31for guiding the first electrical connector7to make the first electrical connector7penetrate the first insulation board53and electrically connect the first circuit board51easily.

FIG.10is a schematic cross-sectional view illustrating a part of the motor10according to an embodiment of the present disclosure. Please refer toFIGS.9and10, the conductive element21extended out from the coil20is electrically connected to the first electrical connector7. The conductive element21is electrically connected to the first electrical connector7by the clamping of the clamp510. The first insulation board53is disposed between the plate31and the first circuit board51as the insulation protection for the electronic components on the first circuit board51. When the first electrical connector7penetrates through the plate31, the waterproof element4is disposed between the first electrical connector7and the plate31. The waterproof element4has an insulating function to prevent the first electrical connector7and the base31from being electrically connected, and also prevent the moisture at the side of the pillow3facing the shaft tube30from passing through the first through hole3101and affecting the circuit boards at the other side of the pillow3.

FIG.11is a schematic cross-sectional view illustrating a part of the motor10according to another embodiment of the present disclosure. Compared with the embodiment shown inFIG.10, the difference is that the conductive element21aofFIG.10extended out from the coil20penetrates through the waterproof element4and is electrically connected to the first circuit board51directly. The corresponding relations and functions of the other components are the same as those inFIG.10, and are not redundantly described herein.

Please refer toFIGS.12and13.FIG.12a schematic exploded view of the motor10according to still another embodiment of the present disclosure, andFIG.13is a schematic exploded view of the motor10ofFIG.12at another viewing angle. In this embodiment, the motor10also includes the stator1, the rotor9, the first circuit board51, the second circuit board52, the first insulation plate53and the second insulation plate54which have similar structures and connection relationships with the embodiments described above, so as to be omitted in the following descriptions. InFIGS.12and13, the rotor9is assembled on the stator1for more clearly showing the structures of other elements. The difference between this embodiment and the embodiment shown inFIGS.4and5is a third insulation plate56is further disposed between the second circuit board52and the cover34for insulating and protecting the electronic components on the second circuit board52. In addition, the third insulation board56also defines a space for accommodating the second circuit board52collaboratively with the second space541formed by the side wall542of the second circuit board52.

A protruding element544is disposed on the second insulation plate54, protruded into the second space541and extended toward the second circuit board52and the third insulation plate56. A fixing element561corresponding to the protruding element544is disposed on a side of the third insulation plate56facing the second circuit board52. A penetrating hole521corresponding to the protruding element544is disposed on the second circuit board52. Accordingly, as the protruding element544passes through the penetrating hole521and is combined with the fixing element561, the second insulation plate54and the third insulation plate56are assembled together to position the second circuit board52in the space therebetween and also provide the insulation protection.

Please refer toFIGS.14and15.FIG.14is a schematic cross-sectional view illustrating the motor10ofFIG.12, andFIG.15is a schematic perspective view illustrating a clip6in the motor10ofFIG.12. The clip6is a single-piece metal and is divided into an abutting portion61, a holding portion62and a clipping portion63. The abutting portion61and the clipping portion63are positioned at opposite sides of the holding portion62and approximately facing each other. For example, in some embodiments, the clip6is formed by bending two ends of a long-shaped metal piece toward the same direction. With the property of one-piece formed metal and the flexibility of thin metal material, the abutting portion61and the clipping portion63of the clip6which are opposite to each other can provide forces in opposite directions to structures and/or objects located therebetween.

FIG.16Ais a schematic enlarged view of the square C ofFIG.14, and please refer toFIG.14andFIG.16A. The abutting portion61of the clip6is abutted against the electronic component520, such as an IGBT (Insulated Gate Bipolar Transistor), on the second circuit board52. The clipping portion63of the clip6is stretched into a trough3231which is formed between the flat region323and the cylinder32of the pillow3. Since the abutting portion61and the clipping portion63provide forces in opposite directions to keep the structures therebetween staying closed, the electronic component520is pushed toward and kept close to the flat region323accordingly. As known, the entire pillow3is a metal structure, so that the heat produced by the electronic component520, which is kept close to the flat region323, can be transmitted to and dissipated through the cylinder32and also the pillow3. Further, since the clip6is also made by metal, the heat produced by the electronic component520also can be transmitted to and dissipated through the clip6, thereby enhancing the efficiency of heat dissipation.

Please refer toFIGS.16AandFIG.16B.FIG.16Bis a schematic perspective view illustrating a combination of the clip6and the cylinder32from a direction of the cover34of the motor10. A screwing hole64is disposed on the holding portion62of the clip6, and a screwing slot3232corresponding to the screwing hole64is disposed at a position between the flat region323and the trough3231. Accordingly, by means of penetrating a screw through the screwing hole64and into the screwing slot3232, the clip6can be screwed and fixed on the pillow3, so as to further stabilize the contact between the electronic component520and the flat region323.

Please refer toFIG.16C.FIG.16Cis a schematic cross-sectional view illustrating a part of a combination of the clip6, the third insulation plate56and the electronic component520. A retaining element562is disposed at the side of the third insulation plate56facing the second circuit board52for correspondingly engaging with the holding portion62of the clip6. In addition to the clip6is screwed on the pillow3through the screwing hole64, the engagement between the holding portion62and the retaining element562provides a further force for fixing the third insulation plate56. Consequently, through the protruding element544penetrates the penetrating hole521of the second circuit board52to combine with the fixing element561, and the clip6is screwed with the screwing slot3232of the pillow3(as shown inFIGS.16A and16B) and engaged with the retaining element562, the second insulation plate54and the third insulation plate56are fixedly maintained together and form the space therebetween, thereby positioning and protecting the second circuit board52therein. Moreover, a division563is disposed on the side of the third insulation plate56facing the second circuit board. The division563is located at a position near the clip6and extended toward the second circuit board52, so that the clip6can be substantially separated from other electronic components disposed on the second circuit board52, thereby preventing the clip6made by metal material from affecting other electronic components, such as to cause a short circuit.

In some embodiments, the second insulation plate54is benefit of increasing the creepage distance and the electrical clearance from the second circuit board52to a charged metal body. In some other embodiments, the third insulation plate56prevents objects from entering the second circuit board52as the cover34is opened. In some other embodiments, an interspace is maintained between the third insulation plate56and the cylinder32for the need of repair. In some other embodiments, the third insulation plate56is formed to have a profile matching to the shapes of electronic components on the second circuit board52, so that the occupied space can be minimized without altering the dimensions of the pillow3and the motor10.

Please refer toFIGS.12and13. A sealing element341is disposed on a periphery of the cover34at a side facing the third insulation plate56. The sealing element341seals the first space321as the cover34is assembled on the cylinder32for achieving a waterproof effect. Preferably, the sealing element341is made of rubber or plastic, but not limited thereto. The first space321formed by the cylinder32and the cover34accommodates, sequentially in a direction from the plate31to the cover34, the first insulation plate53, the first circuit board52, the second insulation plate54, the second circuit52, and the third insulation plate56.

From the above descriptions, the present disclosure provides a motor. By installing the circuit board to replace the wire binding plate of the conventional motor, the steps and complexity of assembling the motor are simplified, and the volume occupied by the motor winding can be eliminated. Furthermore, the waterproof element is disposed in the insertion hole, and the waterproof element is configured for the electrical connector to penetrate therethrough and can achieve the waterproof and insulation functions meanwhile. In addition, in the pillow of the motor, multiple insulation plates are disposed for fixing and protecting the circuit boards, and the clip is also provided for facilitating the fixing and heat dissipation of the electronic component on the circuit board.

While the disclosure has been described in terms of what is presently considered to be the most practical and preferred embodiments, it is to be understood that the disclosure needs not be limited to the disclosed embodiment.