METHOD OF MAKING ROTOR OF BRUSHLESS MOTOR

• US 20080313884A1
• Filed: 08/14/2008
• Published: 12/25/2008
• Est. Priority Date: 05/11/2007
• Status: Active Grant

• Current Assignee: Bluffton Motor Works LLC (Wpa Participações e Serviços SA)
• Original Assignee: SNTech Incorporated
• Inventors: Jeung, Young-Chun
• Granted Patent: US 8,033,007 B2
• Time in Patent Office: Days
• US Class Current: 29/598
• CPC Class Codes: H02K 1/2733 Annular magnets
• CPC Class Codes: H02K 1/30 using intermediate parts, e.g. spiders
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49011 Commutator or slip ring assembly
• CPC Class Codes: Y10T 29/49012 Rotor
• CPC Class Codes: Y10T 29/53143 Motor or generator

Abstract

Some embodiments of the present disclosure provide a method of making a rotor of an electric brushless motor configured to be light weight and prevent vibrations generated during an operation of the motor to be transferred to the shaft of the rotor. The method includes providing a shaft elongated in a rotational axis, providing a single body magnet comprising alternately magnetized portions, and providing a vibration absorption portion interposed between the shaft and single body magnet. The vibration absorption portion absorbs vibrations generated during the operation of the motor and may include an elastic or a non-elastic material. The method further includes providing a non-elastic portion configured to inhibit the expansion of the vibration absorption portion when the vibration portion is elastic.

Claims

1. A method of a making a rotor, the method comprising:

providing a shaft elongated in an rotational axis;

providing a vibration absorption portion outside a portion of the shaft;

providing one or more body magnets such that the vibration absorption material is interposed between the elongated shaft and the one or more magnets.

2. The method of claim 1, further comprising:

forming an engagement enhancing layer on a portion of the shaft.

3. The method of claim 2, wherein the shaft comprises a roughened surface, wherein the engagement enhancing layer is formed at least on the roughened surface of the shaft.

4. The method of claim 2, wherein forming the engagement enhancing layer comprises injection molding onto the shaft.

5. The method of claim 2, further comprising:

forming the vibration absorption portion over the engagement enhancing layer so as to integrate the vibration absorption portion with the shaft.

6. The method of claim 5, wherein forming the vibration absorption portion comprises injection molding.

7. The method of claim 2, wherein a portion of the vibration absorption portion contacts a portion of the shaft.

8. The method of claim 1, wherein the vibration absorption portion comprises a pored structure wherein providing the vibration absorption portion outside the shaft comprises engaging the pored structure with the shaft with or without an engagement enhancing layer between the shaft and vibration absorption portion.

9. The method of claim 1, wherein the vibration absorption portion comprises an elastic material, wherein the method further comprises:

providing a non-elastic portion outside the vibration absorption portion, wherein the non-elastic portion does not comprise an elastic material, wherein the single body magnet is subsequently engaged with the non-elastic portion.

10. The method of claim 9, wherein the non-elastic portion comprises a cylindrical portion, wherein providing the non-elastic portion outside the vibration absorption portion comprises:

arranging the non-elastic portion and the shaft such that the non-elastic portion and the shaft define a space therebetween; and

injecting an elastic material into the space so as to form the vibration absorption portion interposed between the non-elastic portion and the shaft.

11. The method of claim 10, wherein the non-elastic portion comprises a plurality of through holes in the cylindrical portion, wherein the elastic material fills the through holes and protrudes outwardly and forms a plurality of protrusions outside the non-elastic portion.

12. The method of claim 11, wherein the plurality of protrusions are engaged with the body magnets.

13. The method of claim 9, wherein the non-elastic portion is annular and surrounding the vibration absorption portion.

14. The method of claim 9, wherein the non-elastic portion is not annular while being interposed between the single body magnet and the vibration absorption portion.

15. The method of claim 9, wherein the non-elastic portion comprises a ferromagnetic material.

16. The method of claim 9, wherein the non-elastic portion does not comprise a ferromagnetic material.

17. The method of claim 9, wherein providing the non-elastic portion comprises injection molding over the vibration absorption portion.

18. The method of claim 9, wherein the non-elastic portion comprises at least one of protrusion and recess on an outer circumference, wherein the single body magnet comprises at least one counterpart configuration configured to engage with the at least one of protrusion and recess.

19. The method of claim 9, further comprising a non-elastic portion interposed between the single body magnet and the vibration absorption portion, wherein the non-elastic portion comprises one or more annular layers.

20. The method of claim 19, wherein the non-elastic portion is engaged with the vibration absorption portion.

21. The method of claim 20, wherein the non-elastic portion comprises at least one of protrusion and recess on an inner circumference, wherein the vibration absorption portion comprises at least one counterpart configuration configured to engage with the at least one of protrusion and recess.

22. A method of making a motor, the method comprising:

providing a rotor comprising;

a shaft;

one or more body magnets comprising alternately magnetized portions; and

a vibration absorption portion interposed between the shaft and the one or more body magnets;

providing a stator comprising a plurality of stator poles; and

assembling the rotor and the stator such that the rotor is to rotate relative to the plurality of stator poles.

23. The method of claim 22, wherein providing the rotor comprises making the rotor, wherein the rotor is made using a method comprising:

providing a shaft elongated in an rotational axis;

providing a vibration absorption portion outside a portion of the shaft;

providing a one or more body magnets such that the vibration absorption material is interposed between the elongated shaft and the one or more body magnets