Rotary motor and production method thereof, and laminated core and production method thereof

• US 5,859,486 A
• Filed: 11/01/1994
• Issued: 01/12/1999
• Est. Priority Date: 11/08/1993
• Status: Expired due to Term

• Current Assignee: Mitsubishi Denki Kabushiki Kaisha (Mitsubishi Electric Corporation)
• Original Assignee: Mitsubishi Denki Kabushiki Kaisha (Mitsubishi Electric Corporation)
• Inventors: Matsumoto, Masaru, Akutsu, Satoru, Hashimoto, Akira, Miyazaki, Hiroshi, Fujita, Youichi, Hasegawa, Tadashi, Nakahara, Yuji, Kawada, Junji, Takai, Yasunori, Azuma, Ken-ichi
• Primary Examiner(s): Stephan, Steven L.
• Assistant Examiner(s): Wallace, Michael J.
• Application Number:
  US08/333,142
• Time in Patent Office: 1,533 Days
• Field of Search: 310/254, 310/258, 310/259, 310/216, 310/217, 310/DIG. 6, 310/71, 310/43, 310/45, 360/86, 360/98.07, 360/99.04, 360/99.08, 360/99.11, 298/596, 298/598
• US Class Current: 310/216.004
• CPC Class Codes: H02K 1/14 Stator cores with salient poles
• CPC Class Codes: H02K 1/146 consisting of a generally annular yoke with salient poles
• CPC Class Codes: H02K 1/148 Sectional cores H02K1/141 takes precedence
• CPC Class Codes: H02K 1/185 to outer stators
• CPC Class Codes: H02K 11/40 Structural association with grounding devices
• CPC Class Codes: H02K 15/022 with salient poles or claw-shaped poles
• CPC Class Codes: H02K 15/095 by laying conductors around salient poles
• CPC Class Codes: H02K 21/14 with magnets rotating within the armatures
• CPC Class Codes: H02K 21/22 with magnets rotating around the armatures, e.g. flywheel magnetos
• CPC Class Codes: H02K 2201/06 Magnetic cores, or permanent magnets characterised by their skew
• CPC Class Codes: H02K 2201/09 Magnetic cores comprising laminations characterised by being fastened by caulking
• CPC Class Codes: H02K 2201/15 Sectional machines
• CPC Class Codes: H02K 2203/03 Machines characterised by the wiring boards, i.e. printed circuit boards or similar structures for connecting the winding terminations
• CPC Class Codes: H02K 2203/06 Machines characterised by the wiring leads, i.e. conducting wires for connecting the winding terminations
• CPC Class Codes: H02K 2203/12 Machines characterised by the bobbins for supporting the windings
• CPC Class Codes: H02K 2211/03 Machines characterised by circuit boards, e.g. pcb
• CPC Class Codes: H02K 29/03 with a magnetic circuit specially adapted for avoiding torque ripples or self-starting problems
• CPC Class Codes: H02K 3/18 Windings for salient poles
• CPC Class Codes: H02K 3/28 Layout of windings or of connections between windings windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32
• CPC Class Codes: H02K 3/522 for generally annular cores with salient poles
• CPC Class Codes: H02K 3/524 : for U-shaped, E-shaped or similarly shaped cores
• CPC Class Codes: H02K 5/225 : Terminal boxes or connection arrangements specially adapted for submersible motors H02K5/132
• CPC Class Codes: H02K 7/14 : Structural association with mechanical loads, e.g. with hand-held machine tools or fans with fan or impeller for cooling the machine H02K9/06
• CPC Class Codes: Y10T 29/49009 : Dynamoelectric machine
• CPC Class Codes: Y10T 29/49073 : by assembling coil and core
• CPC Class Codes: Y10T 29/49078 : Laminated

Abstract

An object of the present invention is to provide a low cost, high performance, thin structure rotary motor for driving medium used in magnetic disk drive unit, optical disk drive unit or the like, in order to improve the productivity of terminating processing and the reliability of the coils. Magnetic materials which are divided to a plurality of blocks or divided corresponding to respective magnetic pole teeth are connected by means of thin portions. The respective magnetic pole teeth are wound continuously with wire without cutting the wire at the positions in which the thin portions are connected. When a stator is assembled, a plurality of blocks or magnetic pole teeth are disposed on a substrate by separating or bending the thin portions.

Claims

1. A rotary motor having n phases, the rotary motor comprising:

a stator portion having an inner circumference and including a stator core comprised of laminated magnetic materials, the stator core including a plurality of blocks and a plurality of thin portions, each thin portion being disposed between and connected to adjacent blocks, each block including n magnetic pole teeth, one corresponding to each of the n phases, extending inwardly toward the inner circumference and n coils disposed about the n magnetic pole teeth;

a rotor portion which is disposed adjacent the inner circumference of the stator portion; and

a molded resin product or a substrate, the stator portion being mounted to the molded resin product or the substrate so the inner circumference of the stator portion faces the rotor portion.

2. The rotary motor according to claim 1, wherein each of the n magnetic pole teeth of each of the plurality of blocks is parallel to one another.

3. The rotary motor according to claim 1, wherein each of the plurality of blocks includes a yoke portion, and at least one coil is disposed on said yoke portion of at least one of the plurality of blocks.

4. The rotary motor according to claim 1, wherein at least one of said plurality of blocks is placed at the same potential level as that of one of a power supply terminal of the coil and a neutral point terminal, and the stator portion forms a connecting terminal.

5. The rotary motor according to claim 1, wherein the stator core includes at least one protrusion having a step arranged facing the substrate, the protrusion being perpendicular to the substrate, the substrate having at least one hole adapted to receive the at least one protrusion to position and fix the stator on the substrate.

6. A rotary motor comprising:

a rotor portion; and

a stator portion including a stator core disposed about said rotor portion, said stator core including,

a plurality of blocks, each block including a plurality of magnetic pole teeth extending inwardly toward the rotor portion,

a plurality of coils disposed about said magnetic pole teeth, said coils comprised of wire being wrapped around the magnetic pole teeth, and

a plurality of crossover wires that interconnect said coils on said magnetic pole teeth, each crossover wire disposed between and interconnecting at least one coil on a block to at least one coil on an adjacent block, wherein said crossover wire is a portion of a continuous length of wire that forms said at least one coil on said blocks.

7. The rotary motor according to claim 6, wherein said magnetic pole teeth include rotor facing surfaces and,

wherein said rotor facing surfaces of the magnetic pole teeth are cut or shaved smooth.

8. The rotary motor according to claim 6,

wherein each of the plurality of blocks includes a yoke portion mounted on a molded resin product or a substrate and each said yolk portion is fused so that adjacent yoke portions are fixed to each other.

9. The rotary motor according to claim 6, wherein the magnetic pole teeth are constructed of magnetic material and

a neutral point is connectable directly to the magnetic material of one of the magnetic pole teeth so that potential of the neutral point is on the same level as that of the magnetic material.

10. The rotary motor according to claim 6, further including a motor shaft having a length,

wherein the magnetic pole teeth include rotor facing surfaces which are formed so as to have a plurality of steps along the length of the motor shaft.

11. The rotary motor according to claim 6, wherein the stator portion includes a rotor facing surface and

wherein the wire is wound around or in the vicinity of the rotor facing surface of the stator portion by several turns.

12. A rotary motor comprising:

a base;

a rotor portion mounted to said base;

a stator portion having a stator core including laminated magnetic pole teeth; and

coils disposed on the magnetic pole teeth; and

a storage container for storing said stator core, said storage container being mountable to said base,

wherein said stator core is bendable about the rotor portion and mounted to said storage container, said storage container being constructed and arranged to fix said stator core in a predetermined position about said rotor portion when said storage container is mounted to said base.

13. The rotary motor according to claim 12,

wherein said stator core is fixed in said predetermined position relative to said rotor portion with a gap therebetween, said storage container including at least one window disposed adjacent said gap for inspecting said gap between said stator core and said rotor portion.

14. The rotary motor according to claim 12,

further comprising a plurality of tying portions disposed parallel to each other and having the same interval spacing as the magnetic pole teeth, said coils being electrically interconnected to and terminated at said tying portions.

15. The rotary motor according to claim 12, wherein a portion of the stator core disposed about the rotor portion is provided without magnetic pole teeth, the motor further comprising:

a magnetic balancer disposed at the portion of the stator core without the magnetic pole teeth,

wherein a gap gb between the magnetic balancer and the rotor is greater than a gap gt between a tip of each of the magnetic pole teeth in the stator core and the rotor.

16. The rotary motor according to claim 15,

wherein the magnetic balancer is fixed in the storage container.

17. The rotary motor according to claim 12,

wherein the magnetic pole teeth include at least a first tooth and a second tooth disposed in parallel to each other in the stator core, the first tooth having a first length and the second tooth a second length, the stator core including a first wire having a first diameter forming a coil around the first tooth and a second wire having a second diameter forming a coil around the second tooth, wherein the first diameter is greater than the second diameter.

18. The rotary motor according to claim 12, wherein the magnetic pole teeth include at least a first tooth having a first length and a second tooth having a second length disposed in parallel to each other in the stator core and a first wire forming a first wire winding position and a second wire forming a second wire winding position, wherein said first and second wire winding positions on the first and second magnetic pole teeth differ depending on the length of the magnetic pole teeth.

19. The rotary motor according to claim 12,

wherein said rotor portion includes a rotor which is concentric with the stator core,

wherein the magnetic pole teeth are grouped into blocks, the teeth forming each block being parallel to each other and wherein said stator core is provided with a portion in which no block is provided, said rotor being placed eccentrically toward said portion in which no block is provided.

20. The rotary motor according to claim 12;

wherein said rotor portion includes a rotor which is concentric with the stator core,

wherein the magnetic pole teeth are grouped into blocks, the teeth forming each block being parallel to each other, said stator core provided with a portion having no block, and wherein a gap between the rotor and the block located opposite the portion of the stator core having no block is larger than a gap between the rotor and other blocks.

21. The rotary motor according to claim 12,

wherein the rotor portion includes a rotor which is concentric with the stator core, and

wherein the magnetic pole teeth are grouped into blocks, the teeth forming each block being parallel to each other and having different lengths, and further comprising trimmed caulking portions for fixing the stator cores disposed on at least one of magnetic pole teeth in the stator core block.

22. A laminated core for a rotary motor, said core comprising:

a plurality of sheets of magnetic material stacked to form the magnetic path of the rotary motor,

said plurality of sheets of magnetic material forming a plurality of block portions and thin portions connecting said block portions, each block portion including a plurality of magnetic pole teeth, said laminated core being bendable at said thin portions, wherein said block portions and said thin portions are integrally formed with said sheets of magnetic material.

23. The laminated core according to claim 22, further comprising:

a plurality of protrusions, at least one protrusion disposed at each end of said thin portions, said protrusions constructed to connect to each other when said thin portions are bent, said protrusions forming fastening member insertion locations for fixing the core in the rotary motor.

24. The laminated core according to claim 22, further comprising:

reinforcing portions constructed to reinforce the thin portions, said reinforcing portions being connected to said block portions adjacent said thin portions.

25. The laminated core according to claim 22,

wherein the plurality of sheets of magnetic materials includes a first group of sheets and a second group of sheets, each of said first group of sheets including first layers of blocks connected to each other with thin portions, each of said second group of sheets including second layers of blocks that are not connected to each other with thin portions.

26. The laminated core according to claim 22, wherein the laminated magnetic sheets are elongated and further comprise:

positioning interfaces on both ends of the plurality of sheets of magnetic material that are adapted to position the laminated core.

27. The laminated core according to claim 22 further comprising:

a pair of protrusions disposed at opposite ends of the thin portions, the protrusions having free ends that are constructed and arranged to be disposed adjacent each other when the laminated core is bent, wherein at least one protrusion has an end face and the protrusions are fixed to each other through the end face.

28. The laminated core according to claim 22,

wherein the stacked sheets of magnetic material are fused to each other at at least one position.

29. The laminated core according to claim 23,

wherein a plurality of sheets of stacked magnetic material are integrally bound to each other at the protrusions at the thin portions.

30. The laminated core according to claim 22, wherein each sheet of magnetic material has a first side and a second side, and

wherein a protruding portion is provided on the first side and a corresponding detent is provided on the second side such that the stacked magnetic materials are engaged through the protruding portion on the first side of one sheet and the corresponding detent of the second side of an adjacent sheet of magnetic material and said sheets are integrally bound together.

31. The laminated core according to claim 22,

wherein edges of at least one sheet of magnetic material of the stacked magnetic materials are rounded.

32. The laminated core according to claim 22,

wherein the edges of the plurality of sheets of magnetic material are rounded and have different radii, and the radius of the edges of the uppermost and lowest sheets of the stacked magnetic materials are larger than of the other edges.

33. the laminated core according to claim 22, wherein the laminated core includes a first face and a second face, and

further comprises insulating plates attached to the first and second faces.

34. The laminated core according to claim 22,

further comprising a wiring sheet having a wiring pattern through an insulator, said wiring sheet being sandwiched between two sheets of the stacked magnetic materials.

35. The laminated core according to claim 22, wherein the laminated core includes an uppermost sheet and lowermost sheet, and

further comprises a magnetic material substrate having a wiring pattern through an insulator attached to one of the uppermost and lowermost of the stacked magnetic materials.

36. A laminated core comprising:

a plurality of stacked layers of magnetic material including outer layers having outer sides,

wherein at least each outer layer is comprised of folded magnetic material that includes first and second portions each having opposing sides, one side having at least one edge including a burr portion thereon and the other side having edges free of burr portions, the first and second portions being folded toward each other with the burr portions being disposed opposite each other, the outer layers of magnetic material being arranged with the edges of the outer sides being free of burr portions.

37. A laminated core for forming a magnetic path for a transformer, the laminated core comprising:

a plurality of stacked magnetic material sheets,

each magnetic material sheet comprised of a substantially U-shaped core portion including a first end and a second end and having a substantially U-shaped opening, a substantially straight yoke portion including a first end and a second end and a thin portion which interconnects the first end of the core portion to the first end of the yoke portion, the thin portion being constructed and arranged to be bent so that the second end of the yoke portion engages the second end of the core portion to close the U-shaped opening with the yoke portion.