KR101397040B1 - Motor, a manufacturing method of the same and a home appliance including the same - Google Patents

Abstract

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a motor, and more particularly, to a motor that reduces manufacturing costs and improves manufacturing and reliability.

The present invention also relates to a method for manufacturing a motor, and to a household appliance including the motor.

According to the present invention, there is provided a stator comprising: a stator core; a stator having an aluminum-made coil wound on the stator core; A rotor rotatably mounted on the stator; A tab terminal on which the end of the coil is located; A mag mate inserted into the tap terminal to be electrically connected to a core wire of the coil and to fix the coil to the tap terminal; And an insulation part provided on the magnet and formed on the exposed part of the core wire by melting when heated.

Motor, aluminum, core wire, tap terminal, insulation

Description

TECHNICAL FIELD [0001] The present invention relates to a motor, a method of manufacturing the same, and a home appliance including the same,

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a motor, and more particularly, to a motor that reduces manufacturing costs and improves manufacturing and reliability.

The present invention also relates to a method for manufacturing a motor, and to a household appliance including the motor.

The motor according to the present invention may be a motor that is relatively bulky, such as a washing machine, a drier, or a dishwasher, and is applied to a home appliance having a high humidity environment and a room temperature higher than the room temperature.

Generally, the motor transmits the rotating force of the rotor to the rotating shaft, and the rotating shaft drives the load. For example, the rotary shaft may be connected to the drum of the washing machine to drive the drum, and the fan may be connected to the fan of the refrigerator to supply cool air to the required space.

On the other hand, in such a motor, the rotor is rotated by electromagnetic interaction with the stator. To this end, a coil is wound on the stator, and the rotor rotates with respect to the stator as current is applied to the coil.

The coil is generally formed of a copper material. This is because the copper material has a very good electrical conductivity and is excellent in ductility, so that there is little damage during winding.

However, the copper material generally has a very high cost, and thus the manufacturing cost of the motor is increased. In addition, there are many cases where stable supply of raw materials is not achieved due to the surge in copper prices internationally.

Therefore, it is necessary to use a coil made of a material other than a copper-made material to reduce the manufacturing cost of the motor, and to supply and receive raw materials stably. In addition, even if coils of different materials are used, it is necessary to manufacture a motor at least equal in quality to that of a conventional copper coil.

On the other hand, when the coil made of copper is replaced with a coil made of another material, it is preferable not to change the conventional configuration largely. This is because, even if the cost of the coil itself is reduced, if the other required components are newly designed and manufactured, the initial facility investment cost may increase excessively.

SUMMARY OF THE INVENTION The present invention is basically aimed at solving the above-mentioned problems.

More specifically, the object of the present invention is to reduce the manufacturing cost of the motor as a whole by reducing the cost of the coil, and to reduce the cost of the household electric appliances as a whole by applying such a motor.

It is also an object of the present invention to provide a motor that reduces the manufacturing cost of the motor and is easy to manufacture, has improved reliability and product durability, and a method of manufacturing the same.

In addition, it is an object of the present invention to provide a motor having a quality equal to or higher than the quality of a conventional motor without significantly changing the conventional essential components, and a home appliance including the same.

According to an aspect of the present invention, there is provided a stator comprising: a stator core; and a stator having an aluminum-made coil wound on the stator core; A rotor rotatably mounted on the stator; A tab terminal on which the end of the coil is located; A mag mate inserted into the tap terminal to be electrically connected to a core wire of the coil and to fix the coil to the tap terminal; And an insulator provided on the magnet and formed on the exposed portion of the core wire by melting when heated.

Preferably, the magmate includes front, rear, and bottom portions, and a slot through which the coil is inserted is formed at an intermediate portion of the front portion, the rear portion, and the bottom portion.

In order to reinforce the rigidity of the magnet, the front and rear portions are parallel and the bottom portion is formed to be perpendicular to the front portion and the rear portion, respectively. The tab terminal may include an upper portion parallel to the lower portion, and may be formed as a generally vertical cross-section having both sides opened in a '?' Shape.

On the other hand, the front or rear portion of the magnet may protrude for electrical connection with the outside. That is, when the magmate is inserted into the tap terminal, the magnet can be electrically connected to the outside through the protruding portion.

In addition, the upper portion of the magmate may be formed to be bent so as to be inclined to the inside of the magmate. The bending portion is also for electrical connection to the outside. Here, the bent portion is for facilitating connection by an elastic force when a terminal for electrical connection is inserted from the outside.

The insulating portion may be provided in the slot portions of the front portion and the rear portion of the magmate. Here, the insulating portion may be a thermosetting type film adhered to the magmate. The insulator may be provided on the front and rear inner and outer walls of the magnet.

The insulator may be provided at a portion of the magmate other than a portion contacting the core wire.

Here, the insulating portion may be provided in the entire region of the magmate except for a portion contacting the core wire, or may be provided only around a portion contacting the core wire. The former may be for electrical connection only between the magmate and the coil, and the latter may be for simultaneous electrical connection with the outside. In the case of the former, the insulating portion can be easily formed by being coated on the magmate, and in the latter case, the thermosetting type film can be easily formed by attaching to the magmate.

In any case, it is preferable that the insulating portion is formed of a material that is melted when heated, and preferably, can be hardened. Therefore, an insulation film may be formed at a portion where the magnet is in contact with the core wire, and the reinforcement function may be performed by curing.

The motor may further include an insulator provided between the stator core and the coil to insulate the stator core from the coil. The tab terminal may be provided on the insulator, or may be integrally formed with the insulator.

The tap terminal may be a power connection tap terminal or a neutral point tap terminal.

To achieve the above object, the present invention also provides a stator having a stator core and an aluminum-made coil wound on the stator core; A rotor rotatably mounted on the stator; A tab terminal on which the end of the coil is located; A magmate inserted into the tap terminal to be electrically connected to a core wire of the coil and to connect the coil to an external power source; And an insulation part which is provided in the magmate and is melted when heated to form an insulation coating on an exposed part of the core wire.

The magmate may include a slot into which the coil is inserted and a connection unit connected to an external power source. Here, the connection may be a specific part of the magmate as described above. That is, the connection portion may be formed to protrude outside the tap terminal of the magmate, or may be a portion inclined inward.

The motor may further include a connector coupled to the tap terminal and electrically connected to the connection to apply external power to the coil.

Further, the motor may include a bracket or a housing forming an outer shape of the motor, and the tap terminal may be provided in the bracket or the housing.

According to an aspect of the present invention, there is provided a method of manufacturing a stator, comprising: (a) winding an aluminum coil on a stator core; Positioning the end of the coil at the tab terminal; (C) inserting a magmate into the tap terminal to electrically connect the core wire of the coil and the magmate, and fixing the coil to the tap terminal; And forming an insulating coating on the exposed portion of the core wire for corrosion prevention and strength reinforcement of the core wire.

Here, the step (d) may include heating the magnetite to melt the insulation provided in the magnetite. The step (d) may further include the step of curing the insulating portion after melting.

In addition, the step (d) may include a step of applying a resin material to the tap terminal.

In order to achieve the above-mentioned object, the present invention also provides a semiconductor device comprising: a base; A stator having a stator core and an aluminum coil wound around the stator core, the stator being fixed to the base; A rotor rotatably mounted on the stator; A tab terminal on which the end of the coil is located; A magmate inserted into the tap terminal to be electrically connected to a core wire of the coil and to connect the coil to an external power source; An insulator provided on the magnet, the insulator being melted when heated to form an insulating coating on an exposed portion of the core wire; And a connector coupled to the tap terminal and in electrical contact with the magnet to apply external power to the coil.

Here, the base may be a bracket or a housing forming the outer shape of the motor. The motor secures the stator to the bracket or housing first, and the bracket or housing is fixed or coupled to the appliance. In other words, in this case, the motor can be said to be coupled to the household appliance through the bracket or the housing. Thus, the base here may refer to a specific part of the household appliance to which the bracket or housing is coupled.

On the other hand, such a bracket may not be necessary since it may be located inside the appliance. For example, the stator can be directly coupled to the tub rear wall of the washing machine. Accordingly, in this case, a portion where the stator is coupled with the tub rear wall of the washing machine can be referred to as a base.

The electrical appliances may include a strength reinforcing portion formed at one side of the tab terminal to reinforce the strength of the tab terminal and the strength of the coil end. The strength reinforcing portion may be formed integrally with the tap terminal.

The strength reinforcing portion may include an insertion portion into which the coil is inserted and a seating portion on which the coil is seated. The width of the insertion portion is preferably larger than the width of the insertion portion when the coil is inserted. Therefore, once the coil is seated, the coil can be stably fixed without coming out of the seat by the vibration or the like.

Preferably, the seating portion includes a curved surface to increase a contact area with the coil.

According to the present invention, it is possible to reduce the manufacturing cost of the motor as a whole by reducing the cost of the coil applied to the motor, and also to reduce the cost of the electric appliances to which the motor is applied.

Further, according to the present invention, it is possible to provide a motor which is easy to manufacture, has improved reliability and product durability, and a method of manufacturing the same, while reducing manufacturing cost of the motor.

In addition, according to the present invention, there is provided a motor having a quality equal to or higher than that of a conventional motor without significantly changing the conventional essential components.

Particularly, according to the present invention, it is possible to provide a motor and a home appliance in which reliability and durability are improved even when the environment of use is high and the temperature is higher than room temperature.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. The accompanying drawings relate to motors for washing machines. However, the present invention is not limited to the motor for washing machine. In addition, the present invention relates to a household appliance in which such a motor is used, and is not limited to a washing machine as a household appliance.

First, a motor structure according to an embodiment of the present invention will be described in detail with reference to FIGS. 1 and 2. FIG.

1 is an exploded perspective view of a stator of a motor according to an embodiment of the present invention.

The stator 100 mainly includes a stator core 110, an upper insulator 120, and a lower insulator 130.

The stator core 110 includes an annular back yoke 111 and a tooth 112 protruding radially outward along the outer circumference of the back yoke. Fig. 1 shows a stator of an outer rotor type motor that rotates with a rotor described later on the outside of the stator core 110. As shown in Fig. Accordingly, on the contrary, the teeth 112 may protrude radially inward along the inner periphery of the back yoke. In this case, the stator will be a stator of the inner rotor type motor.

The stator core 110 may be formed by laminating a steel sheet. However, when such a method is used, a piece of steel sheet generated in a circular shape inside is not necessary, and there is a lot of room for waste of the material. Therefore, it is preferable that the strip-shaped back yoke and the teeth vertically protruding from the back yoke are laminated while being bent in a spiral shape to be formed into a spiral core. This type of spiral core is shown in Fig.

The caulking portion 113 is formed in the annular back yoke 111 so that the layers are coupled to each other to integrally form the stator core.

A coil (not shown) is wound around the teeth 112. However, since the teeth are generally made of a conductor material, an insulator for insulation is generally provided between the teeth and the coil. Therefore, in the present invention, the insulators 120 and 130 are provided on the upper and lower portions of the stator core 110, respectively. That is, the upper insulator 120 and the lower insulator 130 are coupled with the stator core 110 to enclose the stator core. At this time, the coils are wound on the winding portions 121 and 131 surrounding the teeth 112.

However, unlike the embodiment shown in FIG. 1, the insulators 120 and 130 may be formed integrally with the stator core 110. For example, the stator core may be insert-injected and formed integrally with the insulator. Further, the insulator may be an insulating film (not shown) inserted between the teeth and the teeth.

Inside the insulators 120 and 130 are formed fastening bosses 125 and 135 protruding in the radial direction and the stator 100 is positioned in the fastening boss at the rear wall of the tub (not shown) Fastening holes 126 and 136 are formed.

That is, the fastening hole 126 of the upper insulator and the fastening hole 136 of the lower fastening insulator correspond to each other when the upper insulator, the stator core, and the lower insulator are engaged to form one fastening hole. The entire stator is fixed to the above-mentioned tub or the like through bolts (not shown) or the like to the fastening holes.

In addition, a positioning protrusion 127 may be formed near the fastening hole 126 of the upper insulator. That is, the positioning protrusion is first inserted into a groove (not shown) formed in a tub or the like to determine the position of the stator 100, and then the stator 100 can be fixed to the tub using the bolts or the like.

Of course, the coupling means such as the coupling bosses 125 and 135 and the coupling holes 126 and 136 may not necessarily be configured to fix the stator 100 to the tub, and the outer shape of the motor may be formed (Not shown) or a motor housing (not shown). Herein, the term "bracket" is used for the purpose of fixing the motor to an electric appliance or the like, and the term "housing" is used for the purpose of accommodating the configuration of the motor and the like. However, since the same configuration can simultaneously satisfy the above objects, this configuration is referred to as a bracket hereinafter.

For example, the stator in a motor must be fixed relative to the rotor. Therefore, a structure for fixing the stator is required, and it can be referred to as a base.

Here, the base may be a bracket forming an outer shape of the motor. The motor secures the stator to the bracket first, and the bracket is fixed or coupled to the appliance. In other words, in this case, the motor can be said to be coupled to the household appliance through the bracket. Thus, the base here may refer to a specific part of the household appliance to which the bracket is coupled.

On the other hand, such a bracket may not be necessary since the motor may be located inside the appliance. For example, the stator can be directly coupled to the tub rear wall of the washing machine. Accordingly, in this case, a portion where the stator is coupled with the tub rear wall of the washing machine can be referred to as a base.

In the stator shown in Fig. 1, coils corresponding to the phases u, v and w can be wound. One coil can be wound on one tooth so that one tooth has one stimulus. This is called concentrating, but the greater the magnetic pole of the stator, the smaller the maximum rotational speed of the rotor. Therefore, it is easy to control the motor, and the maximum torque can also be relatively large.

First, when the winding of the u-phase coil is completed on one tooth, the coil is wound and fixed on the coil winding rib 122 formed on the upper insulator, and then the coil is wound again on the next tooth by crossing two neighboring teeth. The start and end of this coil are located in the power connection tap terminal 128 and the neutral point tap terminal 129, respectively. The starting end and the end of such a coil are referred to as terminals for convenience of explanation.

Here, the connector 140 is coupled to the power connection tap terminal, and three phase power is applied to the coils of the u, v, and w phases. In addition, the ends of the coils of the respective phases are electrically connected to each other at the neutral point tap terminal 129 to form a neutral point.

Here, the tab terminals 128 and 129 are formed of an insulating material, and are preferably integrally formed with the insulator. However, the tap terminal may be formed in the above-described base.

At this time, when the coil wound around the stator core is a single phase, the neutral point tap terminal 129 may be omitted.

On the other hand, a hole sensor assembly 141 is fixed to one side of the tap terminal, that is, the power connection tap terminal 128 and the neutral point tap terminal. The Hall sensor assembly senses the position and / or speed of the rotor to be described later, and controls the rotation speed and torque of the rotor by adjusting the phase of the applied voltage and the intensity of the current.

An insulator rib 123 is formed along the circumferential direction inside the coil winding rib 122 in the radial direction. Of course, such an insulator rib 123 is formed not only in the upper insulator but also in the lower insulator. The insulator ribs 123 are formed at a predetermined height or more, and function to prevent the moisture inside the insulator from flowing to the winding portions 121 and 131.

In addition, the insulator rib 123 is preferably formed to be higher than a height at which the coil is wound. This is because when the stator 100 is handled, there is a possibility that the coil may be damaged in other objects around the stator 100. That is, in the case of placing on the floor, only the insulator ribs 123 are brought into contact with the floor, and the coil is not brought into contact with the floor, so that the coil can be prevented from being damaged.

2 is a perspective view showing a rotor of a motor according to an embodiment of the present invention.

The rotor 200 according to the present embodiment includes a rotor frame 210 and a permanent magnet 216.

The rotor frame 210 includes a base 212 and a sidewall 211 formed on the outer side of the base. The rotor frame 210 may be formed by pressing an iron plate. Here, a plurality of permanent magnets are provided along the circumferential direction on the inner side of the side wall part. These permanent magnets are alternately magnetized to the N pole and the S pole along the circumferential direction.

The side wall part 211 performs a back yoke function to form a magnetic path.

Of course, the above-described rotor frame may be formed by injection, and in this case, an annular magnetic back yoke must be separately provided.

In addition, a hub portion 213 protruded upward is formed at the center of the base 212 of the rotor to reinforce the rigidity of the base. A through hole 219 is formed at the center of the hub portion 213, and a rotary shaft (not shown), for example, a rotary shaft of the washing machine is positioned at this portion. The rotation shaft and the hub 213 are connected to each other using a connector (not shown). Accordingly, as the rotor rotates, the rotating force of the rotor is transmitted to the rotating shaft.

The hub 213 may be formed with a coupling hole 214 for coupling the connector 140 or a positioning groove 215 for determining the position of the connector.

The rotor 200 accommodates the stator 100 and rotates with respect to the stator 100 through the interaction of the stator 100. Of course, the rotational force of the rotor is transmitted to the rotating shaft (not shown) which rotates integrally with the rotor frame 210.

The present invention is characterized by using a coil including an aluminum core wire instead of a conventional copper coil. The aluminum material has a larger internal resistance than the copper material. Therefore, in order to reduce the internal resistance, it is necessary to increase the outer diameter as compared with the conventional copper material coil.

In addition, the aluminum material is less ductile than the copper material. Therefore, there is a fear that the coil is easily broken due to an external impact upon winding. In addition, the aluminum material is vulnerable to water, especially brine, and when it comes into contact with such brine, it is likely to be easily corroded and broken.

Therefore, in the motor according to the present invention, it is preferable that a coil of aluminum is formed with a double coating film formed outside the core of the aluminum material for reinforcement of strength and ductility. In addition, reliability of the insulation of the coil can be further enhanced through the double coating film.

On the other hand, the end of the coil is located at the tap terminal as described above. In order to electrically connect the ends of such coils, the coating film must be removed so that the core wires are exposed to the outside. Therefore, the end portion of the coil in which the core wire is exposed has a weak strength and ductility as described above, and may easily break. In addition, there is a problem that it can be easily corroded when it comes into contact with water, especially brine.

For example, household appliances such as washing machines, dryers and dishwashers can use hot water as well as cold water, or hot air can be used. Therefore, it operates in a high humidity and high temperature environment. Therefore, especially in these household appliances, the strength and insulation of the end portions of the coil, especially the core wires, will become more important.

Therefore, the present invention is characterized by including an insulating portion for reinforcing the strength of the end portion of the coil, preventing corrosion, and insulating the coil. The insulating portion may be formed in various ways, and the insulating portion will be described in detail below with reference to FIGS. 3 to 12. FIG.

FIG. 3 is an exploded perspective view of a tap terminal and a magmate inserted into the tap terminal, and FIG. 4 is a perspective view showing a state in which a terminal of a coil is positioned at a tap terminal and is electrically connected through a magmate.

The tap terminal may be a power connection tap terminal 128 or a neutral tap terminal 129. However, for convenience of explanation, only the neutral point tap terminal will be described, and the same thing can be applied to the power connection tap terminal. For example, in the neutral tap terminal 129, the coil of each phase, that is, the three coil ends is positioned as shown in FIG. 4, and the power connection tap terminal 128 is provided with a coil of a specific phase, Will be located. Of course, in each case the shape of the magmate may vary. This will be described later.

3 and 4, the tap terminal is formed with a space portion 161 into which the magmate 150 can be inserted. Slits 162 are formed in front and rear of the space, respectively, so that the ends of the coils are engaged with the slits 162 on both sides. Meanwhile, it is preferable that a chamfer 163 or a round is formed on the slit so that the coil can be easily inserted.

Meanwhile, one side of the tap terminal may be connected to the insulator rib 123 described above. That is, it can be formed integrally with the insulator. However, the present invention is not limited to this, and the tap terminal may be formed on the above-described bracket or base. In addition, the tab terminal may be exposed to the outside of the bracket so that the tab terminal and the connector 140 can be easily coupled from the outside of the bracket.

3, the magmate is formed in a 'C' shape, and a slot 151 is formed in the front part 152, the rear part 153, and the lower part 154, respectively. Of course, it is preferable that the slots are formed in the middle portions of the front, rear, and bottom portions. It is preferable that the coils are forcedly inserted in the slots 151 to expose the core wires and are electrically connected to the magmates 150. Therefore, the magmate should be formed of a conductive material. Of course, it may be electrically coupled with the magmate after exposing the core wire in advance.

Here, the magmate may not necessarily have a slot 151. That is, it is possible to electrically connect the core wire to a specific portion of the magmate, and the insulating portion may be formed at the connection portion.

The front portion 152 and the rear portion 153 may be parallel to each other and the lower portion 154 may be perpendicular to the front portion and the rear portion of the magmat 150 for rigidity reinforcement. In addition, the magmate 150 includes an upper portion 155 parallel to the lower portion 154, and may be formed as a whole.

In addition, both sides of the magnet 150 may be opened. In this case, the magnet may be bent to form an overall shape. Hooks 156 may be formed on both sides of the magmate. Of course, grooves or projections (not shown) may be formed in the space portion 161 of the tab terminal 129 corresponding to the hook 156. Therefore, when the magmate 150 is inserted into the tap terminal 129, the magmate 150 is fixed by the hook 156, so that the magmate does not easily escape by vibration or the like.

As described above, after the end of the coil is positioned at the slit 162 of the tap terminal, the magmatic 150 is electrically connected to the space portion of the tap terminal 161 and the core wire may be exposed at the same time. However, after the core wire is exposed, the magmate may be inserted and electrically connected at the same time.

4 shows a state in which the coil end and the magmate are respectively inserted into the tap terminals to form the neutral point.

Figures 5 and 6 schematically illustrate how the magmate and coil ends are electrically connected.

First, the ends of the magmate and the coil 160 are electrically connected to each other inside the tap terminal, and the core wire 165 of the coil and the magmatic material of the conductive material are in direct contact with each other. Therefore, a specific portion of the coil 160 in direct contact with the magmate is in a state where the coating film, particularly the dual coating film 166, is removed.

Therefore, when the coil 160 is shaken or an external impact is applied, there is a fear that the core wire 165 of the coil directly contacting with the magmate is broken as described above. Further, corrosion may occur at this portion. This is because, as described above, the core wire of the coil is formed of an aluminum material.

In order to prevent such a problem, it is preferable that an insulation portion is formed at a portion where the core wire 165 of the coil contacts the magmate. 6 shows a state in which the resin material 170 is applied.

The resin material 170 is formed of an insulating material, and is coated and cured to maintain insulation at the core wire 165 and protect the core wire from the outside. Of course, the external force is directly blocked from being transmitted to the core wire 165 to reinforce the strength of the core wire 165.

7 shows a state in which the resin 170 is applied to the entire tab terminals. That is, the resin 170 is coated so as to cover not only the exposed portion of the magemat 150 and the core wire 165 of the coil but also a portion of the coil 160 where the coating film 166 is not removed.

In this case, although the amount of the resin to be coated can be increased, the end of the coil can be more firmly fixed to the tap terminal, and more reliable insulation and corrosion prevention can be achieved.

Also, in this case, it is preferable that the tap terminal is a neutral tap terminal 129, not a power connection tap terminal 128. This is because the neutral point tap terminal does not need to be electrically connected to other parts other than the coil 160.

Meanwhile, when the tap terminal is the power connection tap terminal 128, the magnetomotive 150 must be connected to the power source. Therefore, it is preferable to prevent the resinous material 170 from being applied to at least a part for such connection.

Here, the magemate 150 may be formed in a different shape to be connected to an external power source, and FIGS. 8 and 9 illustrate an embodiment of the magemate.

As shown in FIGS. 8 and 9, the magnetomotive 150 further includes connection portions 157 and 158 for connection to an external power source.

The connection part 157 may be formed as a part of the front part 152 or the rear part 153 of the magnetmeter and protrude outside the tap terminal 128. Here, the connection part 157 is accommodated in the connector when the connector 140 (see FIG. 1) is coupled with the tap terminal 128, and is connected to an external power source. In other words, the magneto 150 shown in FIG. 8 is further formed with a connection part 157 protruding outside the tap terminal 128 to be connected to an external power source, unlike the magmate shown in FIG.

In addition, the connection portion 158 may be formed in a deformed shape of the upper portion 155 of the magnetomay and be inclined inward. In this case, a terminal provided in the connector 140 is inserted into the inside of the magmate 150 and connected to the connection unit 158, so that electrical connection can be established.

That is, the magnetomotive 150 may further include connection portions 157 and 158 for connection to an external power source, and such connection portions may be provided on the outer side or the inner side of the magmate, if necessary.

Hereinafter, another embodiment of the insulation unit according to the present invention will be described in detail with reference to FIG.

In the above-described embodiment, the core of the coil and the magnet are electrically connected to each other to form an insulating coating, and resin material is applied to the exposed portion of the core wire. That is, the resin 170 applied as an insulating portion is added. However, in the present embodiment, first, the magmate having the insulating part is electrically connected to the core wire of the coil, and then the insulating film is formed through the insulating part.

As shown in FIG. 10, the magmate is provided with an insulation portion on the magnetom. That is, for example, the thermosetting type film 180 may be attached to the magmate. Here, the shape of the magmate may be the same as that of the magmate 150 described above. However, the insulating portion for forming the insulating film is provided in the magmate unlike the above-described embodiment.

10 shows a thermosetting type film 180 attached to a slot 151 portion of the magmate 150. As shown in Fig. Such a film 180 may be attached to the front and back walls of the front portion 152 and the rear portion 153 of the magmate 150. In addition, the film 180 may be attached only around the slot, except for the portion of the slot 151. Of course, since the coil 151 is inserted first in the lower portion 154 of the magemat 150, it is preferable that the film 180 is not provided for such coil insertion.

Meanwhile, the film 180 may be attached to cover the slot 151 formed on the front and rear portions of the magnet 150. In this case, when the coil is inserted, a part of the film 180 may be torn or wrinkled to surround the coil.

Here, as described above, it is preferable that the film 180 is a thermosetting type film which is melted when heated, and then hardened while being cooled. Accordingly, the film 180 is heated and melted to form an insulating film on the core portion of the coil. Then, it is cooled and hardened to form the cross-sectional shape shown in Fig. That is, the film 180 is melted when heated and then cooled to form the insulating coating 170 as shown in FIG.

Therefore, this embodiment can effectively form an insulating portion or an insulating film by using a smaller amount of insulating material than the above-described embodiment. That is, the above-described embodiment applies the resin material, and it is practically difficult to apply the resin material only to the exposed portion of the coil, so a large amount of resin material must be applied. On the contrary, the present embodiment is able to effectively form an insulating film only on the exposed portion of the core wire by melting the insulating portion, for example, the film 180 previously provided in the exposed portion of the core wire.

In addition, in the present embodiment, the film 180 may be a resin material provided in the magmate 150. In other words, it may be a resin material provided around the slot 151 by injection or the like, except for the slot 151 part. However, considering the ease of manufacture and the production cost, the use of the film 180 may be more effective. In addition, according to the present embodiment, it is possible to prevent a problem that may be caused by excessively applying the resin material.

Meanwhile, the above-described embodiments may further include the strength reinforcing portion 239 reinforcing the strength of the tap terminal. This will be described in detail with reference to FIG.

11 shows a neutral terminal 229 as a tap terminal. However, the tap terminal may be a tap terminal 228 for power connection.

This strength reinforcing portion 239 is formed on one side of the tap terminal. More specifically, the strength reinforcement 239 may be formed radially inwardly and / or outwardly of the tab terminal. However, it is preferable to be formed radially outward of the tab terminal in consideration of the convenience of fixing the coil end. Further, it may be formed integrally with the insulator, like the tap terminal.

Here, when the coil 160 generates a tensile force, the strength reinforcing portion 239 does not receive the tensile force directly at the portion where the coil and the magnet 150 are connected, that is, the exposed portion of the core wire, Lt; RTI ID = 0.0 > coil. ≪ / RTI > Therefore, the strength reinforcing portion 239 may be configured to reinforce the strength of the end portion of the coil.

Meanwhile, the strength reinforcing portion 239 may be formed with a slit 241 like the tap terminal. Therefore, the end of the coil is fixed to the slit (241) of the strength reinforcing portion and the slit (162) on both sides of the tab terminal, so that the fixing strength is further strengthened.

It is preferable that the width of the slits 241 and 162 is formed to correspond to the outer diameter of the coil 160. In other words, unlike the case shown in FIG. 11, it is preferable that the coil 160 is formed to be narrower than the outer diameter of the coil 160 including the coating film so that the coils are forced and fixed at the same time. However, it is more preferable to prevent the coating film from becoming too narrow so as not to damage the coating film.

The width of the slit will be the same not only in this embodiment but also in the other embodiments described above.

In addition, the strength reinforcement 239 may be formed with a pocket 240 having a predetermined space formed therein. Preferably, such a pocket communicates with the inside of the tab terminal through the slit 162. Thus, the coil 160 is secured to the tab terminal across the pocket 239.

Also in this embodiment, the resin material 270 can be applied as an insulating portion. In this case, it is not preferable that the amount of the resin to be applied over the tab terminals excessively leaks out of the tap terminals. Therefore, it is preferable to overflow the pockets 240 of the strength reinforcing portion 239 even if the resin overflows. Accordingly, it is possible to apply a predetermined amount of the resin material, so that it is possible to automatically apply the resin material to the resin material, not the manual manner, thereby simplifying the production process.

In addition, since the resin material is applied to many portions, it will be advantageous to more effectively strengthen the strength of the coil end, ensure insulation, and prevent corrosion. In the present embodiment, the insulating film 180 may be applied as the above-described insulating portion.

Meanwhile, the strength reinforcing portion 239 may be formed for fixing the coil 160. This will be described in detail with reference to FIG. As shown in Fig. 12, the strength reinforcing portion 339 is lower in height than the tab terminal 229, unlike the strength reinforcing portion 239 shown in Fig.

The strength reinforcement 239 shown in FIG. 11 may cause the coil 160 to move up and down unless resin material is applied to the pockets 240. On the other hand, according to the strength reinforcing portion 339 shown in FIG. 12, since the coil is fixed, there is no possibility of moving up and down. To this end, the strength reinforcing portion 339 includes an insertion portion 340 into which the coil is inserted and a seating portion 341 on which the coil is seated.

Since the height of the strength reinforcing portion 339 is lower than that of the above-described strength reinforcing portion 239, the material cost can be reduced.

The width of the insertion portion 340 is formed so as to be interference-fit when the coil is inserted, and the width of the seating portion is larger than the width of the insertion portion. Therefore, once the coil is inserted through the inserting portion 340 and seated in the seating portion 341, the coil can be prevented from moving up and down. This is because the coil portion that is seated in the seating portion receives direct tensile force without reinforcing the strength of the coil end without receiving the tensile force directly at the core wire exposed portion of the coil.

In addition, since the coil inserted through the inserting portion 340 is not easily released, it is possible to stably strengthen the end of the coil even after the insertion.

In order to increase the contact area with the coil, the seating part of the strength reinforcing part preferably includes a curved surface as shown in the figure.

According to the present invention described above, a coil including a core wire made of aluminum rather than a conventional copper material is applied. In addition, the present invention is characterized by an insulating part for reinforcing strength, insulation and corrosion prevention of the aluminum core wire. Here, the insulating portion is not limited to the above-described embodiment, and various modifications may be made. However, such modified embodiments are also included in the present invention as long as they belong to the technical idea of the present invention.

Hereinafter, a method for manufacturing a motor according to the present invention will be described.

First, an aluminum-made coil is wound around the stator core. Thereafter, the end of the coil is electrically connected. That is, they form a neutral point or power connection point, which places the ends of these coils in the tap terminal for ease of manufacture and stable wiring.

These tap terminals can be inserted with a magmate for electrical connection and end fixation of the coil. That is, the magmat is connected to the coil located at the tap terminal to form a neutral point between the coils or to form a connection point to be connected to an external power source. Herein, the connection point means the above-mentioned connection portions 157 and 158. [

Therefore, the coil is fixed to the tap terminal through such a magmate, and electrical connection is made.

Thereafter, an insulating film is formed at a portion to which the magmate and the coil end are connected, that is, a portion where the core wire of the coil is exposed. That is, an insulating portion is formed. This insulation part is for preventing corrosion of the core wire and reinforcing the strength.

Here, the insulating portion may be a resin material applied to form an insulating coating on the exposed portion of the core wire. That is, such a resin material forms an insulating film. In addition, the insulating portion may be provided in the magmate, and the insulating portion may be melted to form an insulating coating on the exposed portion of the core wire.

The insulating portion melts by heating, and then is cooled and hardened, thereby performing the function of insulation and strength reinforcement.

1 is an exploded perspective view of a stator of a motor according to an embodiment of the present invention;

2 is a perspective view illustrating a rotor of a motor according to an embodiment of the present invention;

3 is an exploded perspective view of a tap terminal and a magmate according to an embodiment of the present invention;

4 is an assembled perspective view of a tap terminal, a coil, and a magmate;

Fig. 5 is a schematic view schematically showing the coupling of the coil and the magmate shown in Fig. 4; Fig.

FIG. 6 is a schematic view schematically showing a state where an insulating portion is included in a coupling portion of a coil and a magmate shown in FIG. 4; FIG.

FIG. 7 is a perspective view illustrating an embodiment of an insulation unit according to an embodiment of the present invention; FIG.

FIG. 8 is a perspective view illustrating a magmate according to another embodiment of the present invention; FIG.

FIG. 9 is a perspective view illustrating a magmate according to another embodiment of the present invention; FIG.

FIG. 10 is a schematic view schematically showing another embodiment of the insulating portion according to the embodiment of the present invention; FIG.

11 is a perspective view showing still another embodiment of the insulating portion according to the embodiment of the present invention;

12 is a perspective view showing an intensity reinforcing portion according to an embodiment of the present invention.

Description of the Related Art

100: stator 110: stator core

120: upper insulator 128: tap terminal for power connection

129: Neutral tap terminal 130: Lower insulator

150: Magmate 160: Coil

170, 270: insulating film (resin material) 180: insulating film

Claims (26)

A stator core, and a stator having an aluminum-made coil wound on the stator core; A rotor rotatably mounted on the stator; A tab terminal on which the end of the coil is located; A mag mate inserted into the tap terminal to be electrically connected to a core wire of the coil and to fix the coil to the tap terminal; And And an insulating portion provided in the magnet, the insulating portion being melted when heated to form an insulating coating on an exposed portion of the core wire, The magmate includes front, rear, and bottom portions. A slot is formed in an intermediate portion of the front, rear, and bottom portions to insert the coil. Wherein the insulation portion is provided on all of the magmate, the inner wall of the rear portion, and the outer wall. delete The method according to claim 1, Wherein the front and rear portions are parallel to each other and the bottom portion is bent to be perpendicular to the front portion and the rear portion, respectively, for rigidity reinforcement. The method according to claim 1 or 3, Wherein the insulation portion is provided on a portion of the magnetite except the slot portions of the front and rear portions of the magnet. 5. The method of claim 4, Wherein the insulating portion is a thermosetting type film adhered to the magmate. delete The method according to claim 1, Wherein the insulation portion is provided at a portion of the magnetite except a portion contacting the core wire. 8. The method of claim 7, Wherein the insulating portion is a thermosetting type film adhered to the magmate. The method according to claim 1, And an insulator provided between the stator core and the coil to insulate the stator core from the coil. 10. The method of claim 9, And the tap terminal is provided on the insulator. 11. The method of claim 10, And the tap terminal is formed integrally with the insulator. The method according to claim 1, Wherein the tap terminal is a power connection tap terminal or a neutral point tap terminal. A stator core, and a stator having an aluminum-made coil wound on the stator core; A rotor rotatably mounted on the stator; A tab terminal on which the end of the coil is located; A magmate inserted into the tap terminal to be electrically connected to a core wire of the coil and to connect the coil to an external power source; And And an insulating portion provided in the magnet, the insulating portion being melted when heated to form an insulating coating on an exposed portion of the core wire, The magmate includes front, rear, and bottom portions. A slot is formed in an intermediate portion of the front, rear, and bottom portions to insert the coil. Wherein the insulation portion is provided on all of the magmate, the inner wall of the rear portion, and the outer wall. 14. The method of claim 13, Wherein the magnetomay further comprises a connection portion connected to an external power source. 15. The method of claim 14, Wherein the connection portion is formed to protrude outside the tap terminal or be inclined inward. 16. The method according to claim 14 or 15, Further comprising a connector coupled to the tap terminal and in electrical contact with the connection to apply an external power source to the coil. 16. The method according to any one of claims 13 to 15, Further comprising a bracket forming an outer shape of the motor, And the tap terminal is provided in the bracket. (A) winding a coil of aluminum on the stator core; Positioning the end of the coil at the tab terminal; (C) inserting a magmate into the tap terminal to electrically connect the core wire of the coil and the magmate, and fixing the coil to the tap terminal; And (D) forming an insulating coating on the exposed portion of the core wire for corrosion prevention and strength reinforcement of the core wire, (D) attaching a thermosetting type film to the front and rear inner and outer walls of the magmate, heating the melted thermosetting film, and curing the thermosetting type film. delete 19. The method of claim 18, Wherein the step (d) further comprises the step of applying a resin material to the tap terminal. Base; A stator having a stator core and an aluminum coil wound around the stator core, the stator being fixed to the base; A rotor rotatably mounted on the stator; A tab terminal on which the end of the coil is located; A magmate inserted into the tap terminal to be electrically connected to a core wire of the coil and to connect the coil to an external power source; An insulator provided on the magnet, the insulator being melted when heated to form an insulating coating on an exposed portion of the core wire; And And a connector coupled to the tap terminal and in electrical contact with the magnet to apply external power to the coil. 22. The method of claim 21, And a strength reinforcing portion formed at one side of the tap terminal to reinforce the strength of the tap terminal and the strength of the coil end. 23. The method of claim 22, Wherein the strength reinforcing portion is formed integrally with the tap terminal. 24. The method according to claim 22 or 23, Wherein the strength reinforcing portion includes an insertion portion into which the coil is inserted and a seating portion on which the coil is seated. 25. The method of claim 24, Wherein a width of the insertion portion is formed so as to make interference fit when the coil is inserted, and a width of the seating portion is larger than a width of the insertion portion. 26. The method of claim 25, Wherein the seating portion includes a curved surface to increase a contact area with the coil.

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