DE202009015390U1 - Plastic DC motor - Google Patents

Abstract

DC motor, consisting of at least
- A rotor (1) having at least one magnetic ring (11, 12) with at least one magnetic element (12.1, 12.2), and
A stator (2) which has at least one stator winding element (21) with coil elements (21.1, 21.2) which are arranged at least partially in a stator body (24, 25),
wherein rotor (1) and stator (2) are movable relative to one another and are kept at a distance by at least one air gap (22, 23),
characterized,
in that the coil elements (21.1, 21.2, 21.3) are embedded in a stutteror body of an at least partially magnetically conductive plastic (25).

Description

• – einem Rotor, der wenigstens einen Magnetring mit wenigstens einem Magnetelement aufweist, und
• – einem Stator, der wenigstens ein Statorwicklungselement mit Spulenelementen aufweist, die wenigstens teilweise in einem Statorkörper angeordnet sind,

wobei Rotor und Stator gegeneinander bewegbar und durch wenigstens einen Luftspalt auf Abstand gehalten sind.The invention relates to a DC motor, consisting of at least

• - A rotor having at least one magnetic ring with at least one magnetic element, and
• A stator having at least one stator winding element with coil elements at least partially arranged in a stator body,

wherein the rotor and stator are movable relative to each other and held by at least one air gap at a distance.

A DC motor of the type mentioned is from the WO 2008 092 630 A1 known. It has a rotor and a stator, wherein the rotor and stator are movable relative to each other and are kept at a distance by air gaps. The coil elements of the stator winding element are designed as flat coils. The Flachsulmente are embedded side by side in a stator plastic body. Furthermore, magnet elements are present in the rotor, which are poled in the radial direction both in the north-south direction and in the south-north direction.

This DC motor has proven itself with its construction. Indeed The shape of the rotary motion could be improved.

From the DE 691 26 125 T2 a dynamoelectric machine is known, which consists of a cylindrical stator having a stator surface about which rotates in a rotation axis separated by an air gap, a cylindrical outer rotor having a cylindrical surface. On the rotor surface is a plurality of magnetic poles. On the stator surface is a substrate formed of a substantially non-conductive, substantially non-magnetic material. An annular layer consisting of a plurality of turns of a annealed steel wire is arranged thereon.

Ultimately, out of the DE 92 13 224 U1 a coil assembly is known, which consists of a wound coil of insulated winding wire, in which a core of a thermoplastic, ferrite-filled material is formed.

It the task arises, a DC motor of the aforementioned To develop the kind so that the rotor movements more evenly become.

According to the invention this object is achieved in that the coil elements in a stutteror body of one at least partially magnetic embedded in conductive plastic.

The particular advantages of the invention are that the magnetically conductive plastic can be shaped like this, that the magnetic flux without resistance and, above all, evenly is passed on. The rotor moves smoothly and evenly opposite the stator. The motoring culture of the engine will significantly improved.

In The dependent claims are advantageous developments of specified in claim 1 features.

The Coil elements may be in the magnetically conductive plastic be embedded so that at least partially core body and at least partially at least one flux guide is trained.

The Core body, the coil elements partially to complete completely. Below and / or sideways from them, the Flußleitkörper can be formed become. This allows the magnetic flux and / or the Specifically influence the rotational force.

So can be embedded in the magnetically conductive plastic Coil elements at least partially of a stator plastic body be surrounded.

• – Bei der ersten Variante wird zuerst der Statorkunststoffkörper geformt. Danach werden die Spulenelemente eingesetzt, die mit dem und durch den magnetisch leitenden Kunststoff eingepresst werden.
• – Bei der zweiten Variante werden zuerst die Spulenelemente mit dem magnetisch leitenden Kunststoff umspritzt. Darum wird der Statorkunststoffkörper geformt
• – Bei der dritten Variante werden Statorkunststoffkörper und magnetisch leitender Kunststoff um die Spulenelemente geformt.

For the enclosure with the stator plastic body, there are several variants:

• - In the first variant, the stator plastic body is first formed. Thereafter, the coil elements are used, which are pressed with and through the magnetically conductive plastic.
• - In the second variant, the coil elements are first encapsulated with the magnetically conductive plastic. That's why the stator plastic body is shaped
• In the third variant, stator plastic bodies and magnetically conductive plastic are formed around the coil elements.

• – 5 Gew.-% bis 80 Gew.-% magnetisch leitenden Materialkörpern und
• – 40 Gew.-% bis 60 Gew.-% Füllkunststoff

bestehen.The magnetically conductive plastic can out

• - 5 wt .-% to 80 wt .-% of magnetically conductive material bodies and
• - 40 wt .-% to 60 wt .-% filler plastic

consist.

The magnetically conductive material body can be approx. 0.1 mm to 0.5 mm in size.

The magnetically conductive material body can be made of silicon alloys with magnetic preferred direction.

Similar to transformer construction, where texture sheets are used, the "texture bodies" at low field strengths after a special heat treatment, have a high permeability at low field strengths. At a mean induction of 0.1 Vs / m ^{2, they show} three times higher permeability values than hot-rolled materials. Technically and economically favorable magnetically conductive plastics can be manufactured from different core materials.

The magnetically conductive material body can a round, rod-shaped, polygonal or the like geometric configuration to have.

Of the Filling plastic can be a polyethylene, a polyamide or Like. Be plastic.

One Embodiment of the invention is in the drawing and will be described in more detail below. It demonstrate

1 a plastic DC motor in a schematic, seen from above representation,

2a a partial section B of the rotor and stator of a motor according to 1 .

2 B a schematic representation of 1 with a flat winding element in detail,

3 a star connection of flat winding elements of a stator according to 1 in a schematic side view,

4 a section through a stator according to 2a along the line IV-IV and

5 a section through a stator according to 2a along the line VV.

In 1 is shown a brushless plastic DC motor. It consists of a rotor 1 and a stator 2 , which are rotatable against each other.

The rotor 1 has two adjacent magnetic ring elements 11 . 12 on, which are arranged on a support element (not shown). The inner magnetic ring element 11 closes with an inner ring 14 , the outer magnetic ring element 12 with an outer ring 13 from.

Both Magnetic ring elements are manufactured in a two-component injection molding process. So z. B. first a construction ring made of plastic and then the magnetic material.

• – Neodym-Eisen-Bor (NdFeB)
• – Samarium-Cobald (SmCo)
• – Aluminium-Cobald (AlNiCo)
• – Strotium-Ferrit (StFe)
• – Barium-Ferrit (BaFe)

As magnetic material can be used:

• Neodymium Iron Boron (NdFeB)
• - Samarium Cobald (SmCo)
• - Aluminum Cobalt (AlNiCo)
• - Strotium ferrite (StFe)
• - Barium ferrite (BaFe)

Is the magnetic ring element 12 been shaped like him 1 and 2a show certain areas are magnetized so that alternately NS poled magnetic elements 12.1 . 12.2 exist as Permamentmagnete. Each magnetic element here has about a 1½-fold length of a coil element 21.1 . 21.2 ,

Leaving two air gaps 22 . 23 lies between both magnetic ring elements 11 . 12 the stator 2 with a substantially ring-shaped stator winding element 21 consisting of coil elements 21.1 . 21.2 . 21.3 , as 2a shows exists. The coil elements are in a stator body 24 made of plastic.

A coil element 21.1 consists of a plurality of interconnected flat winding elements or manufactured in some other way sub-coils.

In the flat winding elements shown here 3 . 4 (see also 2 B ) are two in a plane opposite plurality of conductor tracks, the beginning of a winding 42 starting at a distance from each other and are guided in a rectangular shape to a coil end. Another special feature is that the coil ends at a folding point 33 . 43 are connected. This is a flat winding pair 3 . 4 in front of that like a 8th looks. Of course, other geometric shapes such as a double hexagon or the like. Possible.

To get out of the flat winding pairs 3 . 4 a coil element 21.1 To be able to produce the flat winding elements are folded so that flat winding element comes to rest on flat winding element. The fold is the plane of rotation or pivot and comes to lie up. Of course, the folding direction can be the other way round.

Are the flat winding pairs 3 . 4 folded, turns winding start 42 the second flat winding element 4 with the winding start 32 the first flat winding element 3 the following flat winding element pair 3 . 4 connected. In this way, the conductor tracks of the flat winding pairs are part of the respective Coil element and thus determine the desired number of turns.

Between the flat winding elements 3 . 4 become upper and lower foil or other insulating elements 44.n and brought everything together to a coil package. The joining can be a pressing. The pressing pressure can be varied accordingly. Regardless of the type of assembly is ensured that the film elements made of plastic or other insulating material penetrates into the distances between the cable runs and the flat winding elements 3 . 4 isolated against each other.

The Motors can be manufactured in micro construction. One Coil package of a coil element can here z. B. a height of about 10 to 15 mm and a width of about 5 to 10 mm. They can also be produced in macro construction.

3 shows an interconnection of the coil elements 21.1 . 21.2 . 21.3 as star connection. Here is the star point 8th led out and the U-winding with 5 using the V-winding 6 and the W-winding with 7 designated. Such a connection is possible due to the specially designed coil elements.

Also a delta connection can be realized.

For special properties, the coil elements can also individually controlled.

The coil elements 21.1 . 21.2 , 21.3 are, in particular the 4 and 5 show in a magnetically conductive plastic 25 edged.

• – 5 Gew.-% bis 80 Gew.-% magnetisch leitenden Materialkörpern 27.1, ..., 27.n und
• – 40 Gew.-% bis 60 Gew.-% Füllkunststoff 26.

The magnetically conductive plastic 25 consists

• - 5 wt .-% to 80 wt .-% of magnetically conductive material bodies 27.1 , ..., 27.n and
• - 40 wt .-% to 60 wt .-% filler plastic 26 ,

The magnetically conductive material body 27.1 , ..., 27.n are about 0.1 mm to 0.5 mm in size.

The magnetically conductive material bodies have a round, rod-shaped, polygonal or the like geometric configuration.

The filler plastic 26 is a polyethylene, a polyamide or the like. Plastic.

The coil elements can thus be in the magnetically conductive plastic 25 be embedded so that at least partially core body 31 and flux collector 28 . 29 . 30 be formed.

The core body 31 can fill the coil elements from partial to complete. The in 4 shown core body 31 has a height h 2 from the bottom coil element 21.1 which is smaller than the window size of the coil. That is, the core body 31 may be formed in the window from 0 to complete filling. At the bottom of the coil element 21.1 is a flux guide 30 arranged, which is also formed from 0 to a height h1 for relining the bottom.

On the left side of the coil elements is with the magnetically conductive plastic 25 a flux collector 28 arranged. This is the right side of a Flussleitkörper 29 across from. The height of the flux collector 28 . 29 is substantially equal to the height h 2 of the core body 30 , When filling with the magnetically conductive plastic 25 h 1 plus h 2 equals the total height h of the flux guides 28 . 29 . 30 and the core body 31 ie h 1 + h 2 = h

By the choice of heights and latitudes is the magnetic flux influenceable, so that the concentricity behavior and the suit strength can be influenced as desired.

The embedded in the magnetically conductive plastic coil elements 21.1 . 21.2 . 21.3 are at least partially of a stator plastic body 24 surround.

• 1. Zuerst wird der Statorkunststoffkörper 24 geformt. Dann werden in den Statorkunststoffkörper 24 die Spulenelemente 21.1, 21.2, 21.3 eingesetzt. Danach wird der magnetisch leitende Kunststoff 25 eingefüllt. Die Spulenelemente werden mit dem und durch den magnetisch leitenden Kunststoff 25 zusammen gedrückt und eingepresst.
• 2. Bei der zweiten Variante werden zuerst die Spulenelemente 21.1, 21.2, 21.3 mit dem magnetisch leitenden Kunststoff 25 umspritzt und die Flussleitkörper 28, 29, 30 sowie die Kernkörper 30 ausgebildet. Um diese Gebilde wird dann der Statorkunststoffkörper 24 geformt.
• 3. Die Spulenelemente 21.1, 21.2, 21.3 werden in einem Werkzeug lagegerecht gehalten. Danach werden im Zweikomponenten-Spritzverfahren die Flussleitkörper 28, 29, 30 sowie die Kernkörper 31 aus dem magnetisch leitender Kunststoff 25 und der Statorkunststoffkörper 24 geformt.

This results for the following production variants:

• 1. First, the stator plastic body 24 shaped. Then be in the stator plastic body 24 the coil elements 21.1 . 21.2 . 21.3 used. Thereafter, the magnetically conductive plastic 25 filled. The coil elements are with and through the magnetically conductive plastic 25 pressed together and pressed.
• 2. In the second variant, first the coil elements 21.1 . 21.2 . 21.3 with the magnetically conductive plastic 25 overmoulded and the Flussleitkörper 28 . 29 . 30 as well as the core body 30 educated. The stator plastic body then turns around these structures 24 shaped.
• 3. The coil elements 21.1 . 21.2 . 21.3 are kept in a correct position in a tool. Thereafter, in the two-component injection process, the Flussleitkörper 28 . 29 . 30 as well as the core body 31 from the magnetically conductive plastic 25 and the stator plastic body 24 shaped.

Which Production variant is selected depends on the possibilities of the manufacturer and the customer requirements from.

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - WO 2008092630 A1 [0002]
• - DE 69126125 T2 [0004]
• - DE 9213224 U1 [0005]

Claims (8)

DC motor, consisting of at least one rotor ( 1 ), the at least one magnetic ring ( 11 . 12 ) with at least one magnetic element ( 12.1 . 12.2 ), and - a stator ( 2 ), the at least one stator winding element ( 21 ) with coil elements ( 21.1 . 21.2 ) which at least partially in a stator ( 24 . 25 ) are arranged, wherein rotor ( 1 ) and stator ( 2 ) movable against each other and by at least one air gap ( 22 . 23 ) are kept at a distance, characterized in that the coil elements ( 21.1 . 21.2 . 21.3 ) in a stutteror body made of an at least partially magnetically conductive plastic ( 25 ) are embedded. DC motor according to claim 1, characterized in that the coil elements ( 21.1 . 21.2 . 21.3 ) in the magnetically conductive plastic ( 25 ) are embedded so that at least partially core body ( 31 ) and at least partially at least one Flußleitkörper ( 28 . 29 . 30 ) is trained. DC motor according to claim 1 or 2, characterized in that in the magnetically conductive plastic ( 25 ) embedded coil elements ( 21.1 . 21.2 . 21.3 ) at least partially from a stator plastic body ( 24 ) are surrounded. DC motor according to one of claims 1 to 3, characterized in that the magnetically conductive plastic ( 25 ) from - 5 wt .-% to 80 wt .-% of magnetically conductive material bodies ( 27.1 , ..., 27.n ) and - 40 wt .-% to 60 wt .-% filler plastic ( 26 ) consists. DC motor according to one of claims 1 to 4, characterized in that the magnetically conductive material body ( 27.1 , ..., 27.n ) are about 0.1 mm to 0.5 mm in size. DC motor according to one of the preceding claims, characterized in that the magnetically conductive material body ( 27.1 , ..., 27.n ) are made of silicon alloys with magnetic preferred direction. DC motor according to one of the preceding claims, characterized in that the magnetically conductive material body ( 27.1 , ..., 27.n ) have a round, rod-shaped, polygonal or the like geometric configuration. DC motor according to one of the preceding claims, characterized in that the filler plastic is a polyethylene, a polyamide or the like. Plastic is.