KR20150022525A - Double rotor type motor having one-body type stator core - Google Patents

Abstract

The present invention provides a double rotor type motor having an integral stator core which can manufacture a stator core in an integral type by extruding amorphous metal powder, soft magnetic powder, or a mixture of amorphous metal powder and soft magnetic powder, thereby reducing mold manufacturing costs through the reduction of core loss and simplifying manufacturing processes. The double rotor type motor having an integral stator core comprises: a stator including a stator core divided into a plurality of parts to be arranged in a ring shape, a bobbin to surround the outer peripheral surface of the stator core, a first coil wound around one side of the stator core, and a second coil wound around the other side of the stator core; an outer rotor disposed on the outer surface of the stator with a predetermined gap therebetween; and an inner rotor disposed on the inner surface of the stator with a predetermined gap therebetween, wherein the stator core includes: a first integral core unit integrally formed of amorphous metal powder and wound with the first coil; a second integral core unit integrally formed by extruding amorphous metal powder through a mold and wound with the second coil; and a laminated connection core unit formed by laminating a plurality of steel pieces and coupled to the first integral core unit and the second integral core unit.

Description

[0001] The present invention relates to a double rotor type motor having a one-piece stator core,

The present invention relates to an integral type stator core capable of realizing a motor with high output, high speed and high torque by integrally molding an amorphous metal powder, a soft magnetic powder or an alloy powder obtained by mixing amorphous metal powder and soft magnetic powder, Type motor having a rotor.

The slotted stator requires a complicated and expensive coil winding arrangement, which is difficult to wind and requires a lot of time for the winding. Also, the structure in which many teeth are formed causes magnetic discontinuity, which affects the efficiency of the motor and causes cogging torque depending on the presence of the slot. In the case of a material such as an electric steel sheet, since the thickness is large, iron loss is large and efficiency in a high-speed motor is inevitably low.

Many of the devices used in various fields, such as the latest technology high-speed machine tools, aviation motors and actuators, compressors, require electric motors that can operate at high speeds exceeding 15,000 to 20,000 rpm and in some cases up to 100,000 rpm. Nearly all high speed electrical devices are fabricated with low excitation factors to ensure that the magnetic material in electrical devices operating at high frequencies does not have too much core loss. This is mainly due to the fact that the soft magnetic material used for most motors is made of Si-Fe alloy. For conventional Si-Fe based materials, losses due to magnetic fields varying at frequencies above about 400 Hz are often heated until the material can not be cooled by any suitable cooling means.

It is known that it is very difficult to provide an electric device which is easy to manufacture at low cost while taking advantage of the advantages of the low-loss material to date. Previous attempts to apply low-loss materials to conventional devices have largely failed because the initial design is simply replacing a conventional alloy such as Si-Fe with a new soft magnetic material, such as amorphous metal, in the magnetic cores of the device It depends on what you do. Although such electrical devices sometimes exhibit improved efficiency with low losses, they generally suffer from significant power degradation and high costs associated with shaping / handling of the amorphous metal. As a result, commercial success or market entry has not been achieved.

On the other hand, typically, the electric motor includes a magnetic member formed from a plurality of laminated laminations made of a non-oriented electrical steel sheet. Each lamination is typically formed by stamping, punching or cutting a mechanically soft non-oriented electrical steel sheet into the desired shape. The formed lamination is then laminated to form a rotor or stator having the desired shape.

Compared to non-oriented electrical steel sheets, amorphous metals provide excellent magnetic performance, but have long been considered unsuitable for use as bulk magnetic members as stator and rotor for electric motors due to certain physical properties and impediments to machining.

For example, amorphous metals are thinner and thinner than non-oriented electrical steel sheets, and thus the fabrication tool and die wear more rapidly. The increase in cost due to tooling and manufacturing makes it less commercially competitive to machine bulk amorphous metal magnetic members as compared to conventional techniques such as punching or stamping. The thickness of the amorphous metal also leads to an increase in the number of laminations of the assembled member and also increases the overall cost of the amorphous metal rotor or stator magnet assembly.

The amorphous metal is supplied as a thin continuous ribbon having a uniform ribbon width. However, amorphous metals are very hard materials and are very difficult to cut or shape easily. When annealed to secure the peak magnetic properties, the amorphous metal ribbon becomes brittle. This makes it difficult and costly to use conventional methods to construct bulk amorphous magnetic members. Also, the embrittlement of the amorphous metal ribbon may cause concern about the durability of the bulk magnetic member in the application of the electric motor.

In consideration of this point, Korean Patent Laid-Open No. 2002-63604 has proposed a low-loss amorphous metal magnetic component having a polyhedral shape and composed of a plurality of amorphous strip layers for use in a high-efficiency electric motor. The magnetic component can be operated in the frequency range of about 50 Hz to 20,000 Hz and has a core loss to exhibit improved performance characteristics compared to a silicon-hard magnetic component operating in the same frequency range. In order to form a polyhedral shape, A metal strip is cut to form a plurality of cutting strips each having a predetermined length and then laminated using epoxy.

However, the Korean Unexamined Patent Publication No. 2002-63604 and the like disclose that the amorphous metal ribbon having a large brittleness is still manufactured through a forming process such as cutting, and therefore, it is difficult to put it into practical use, and it is operated in a frequency range of 50 Hz to 20,000 Hz, Applications for frequency are not proposed.

Korean Patent Laid-Open Publication No. 2005-15563 discloses a method for producing an amorphous metal ribbon, which comprises preliminarily heat-treating an amorphous metal ribbon produced by a rapid solidification method using an Fe-based amorphous alloy, pulverizing the amorphous metal ribbon to obtain an amorphous metal powder, Mixing the powder with a powder particle size distribution having an optimal composition uniformity after classifying the powder, mixing the mixed amorphous metal powder with a binder, and then molding the core, and after the formed core is annealed, Of the amorphous soft magnetic core is coated with an insulating resin.

The core is used in a smoothing choke core of a switching mode power supply (SMPS) or the like so that the DC superposition characteristic of the magnetic core with respect to the waveform in which the DC is superimposed on the weak alternating current generated in the process of converting the AC input of the power supply device into DC It is used for the purpose of improvement.

Korean Patent Registration No. 721501 discloses a method of manufacturing an amorphous alloy ribbon, which comprises preliminarily heat-treating an amorphous alloy ribbon, classifying the powder obtained by pulverizing the amorphous alloy powder obtained by pulverizing the preliminarily heat-treated amorphous alloy ribbon, Comprising the steps of: mixing a powder with a polyimide-based resin with a binder of a polyimide-based resin; pressing the mixed powder; and heat treating the pressed powder core for nanocrystallization A method has been proposed.

The powder cores are applied to a current transformer, an earth leakage breaker, a smoothing choke, and the like for high power applications.

On the other hand, when a high-speed motor having a high output of 100 kW and a speed of 50,000 rpm, such as a driving motor for an electric automobile, is implemented using a silicon steel sheet, heat generation is a problem as the Eddy Current increases due to high- In addition, since it is manufactured in a large size, it can not be applied to a drive system of an in-wheel motor structure, and it is not preferable from the viewpoint of increasing the weight of an automobile.

In general, the amorphous strip has a low Eddy Current Loss, but the conventional motor core formed by winding or forming and laminating the amorphous strip has difficulty in practical use due to difficulties in the manufacturing process .

As described above, the conventional magnetic steel sheet provides excellent magnetic performance as compared with the non-oriented electrical steel sheet. However, the magnetic steel sheet can not be used as a stator for an electric motor and as a bulk magnetic member due to a trouble occurring during manufacturing.

Further, the conventional method of manufacturing an amorphous soft magnetic core has not proposed a design method of a magnetic core that is optimal for an electric motor field having high output, high speed, high torque, and high frequency characteristics.

Furthermore, there is a need for improved amorphous metal motor members that exhibit a combination of good magnetic and physical properties required for high speed, high efficiency electrical appliances. There is a need for the development of manufacturing methods that can be used for the efficient use of amorphous metals and for the mass production of various types of motors and magnetic components used therein.

Korean Patent Publication No. 2002-63604 Korea Patent Publication No. 2005-15563 Korea Patent No. 721501

An object of the present invention is to reduce the core loss by integrally manufacturing a stator core by compression-molding a mixture of an amorphous metal powder, a soft magnetic powder or a mixture of an amorphous metal powder and a soft magnetic powder to simplify the manufacturing process Type motor having an integral stator core that can be used as a stator core.

Another object of the present invention is to provide a further blotter type motor having an integral stator core that can be made slim by reducing the height of the axial stator core by integrally forming the stator core.

Still another object of the present invention is to provide a further rotor type motor having an integral stator core capable of designing the same height of the stator core and the first and second magnets of the double rotor to improve the motor efficiency.

It is a further object of the present invention to provide a stator core in which a portion where the first coil and the second coil are wound is formed as an integral core portion and a connecting portion connecting between the stator cores having a complicated shape is formed as a laminated connecting core portion, Type motor having an integral stator core that is manufactured by mutually combining the integral core portions.

In order to achieve the above object, the motor having the integral stator core of the present invention comprises: a stator core divided into a plurality of parts and arranged in an annular shape; a bobbin wrapped around an outer peripheral surface of the stator core; A stator having a coil and a second coil wound on the other side of the stator core; an outer rotor disposed at an outer surface of the stator with a predetermined gap therebetween; and an inner rotor disposed at an inner surface of the stator with a predetermined gap therebetween The stator core includes a first integral type core portion formed by compression molding of an amorphous metal powder and integrally formed by a metal mold and a first coil wound around the stator core and a second integral type core portion formed by compression molding of the amorphous metal powder, A first integral core portion and a second integral core portion which are formed by laminating a plurality of iron pieces, The connection may comprise bonded laminate core portion.

Wherein the first integral type core portion includes a first yoke portion around which the first coil is wound and a first flange portion integrally formed at one end of the first yoke portion and facing the outer rotor, A second yoke portion around which the second coil is wound, and a second flange portion integrally formed at one end of the second yoke portion and disposed to face the inner rotor.

The first and second yoke portions and the second yoke portion have upper and lower surfaces formed with coil springs lower than the upper and lower surfaces of the first flange portion and the second flange portion, A first coil reduction groove formed on the upper surface of the first yoke portion and the second yoke portion and inwardly inward by a depth H8 of the upper surface of the first flange portion and the second flange portion, And a second coil reduction groove formed inside the first flange portion and the second flange portion by a depth (H9) as compared with a lower surface of the first flange portion and the second flange portion.

The first integrated core portion and the second integrated core portion may be compression molded into a mixture of an amorphous metal powder and a spherical soft magnetic powder.

Wherein the laminated connection core portion includes a connection portion formed with a first press-fit groove for press-fitting the first integrated core portion on one surface and a second press-fit groove formed on the other surface for press-fitting the second integrated core portion, And a latch groove formed on the other side surface of the connection portion and engaged with the latch projection.

The lamination height of the laminated connection core portion may be the same as the height of the first yoke portion and the second yoke portion.

The height of the first magnet and the second magnet of the outer rotor and the inner rotor may be the same as the height of the first flange and the second flange.

As described above, the blotter type motor having the integral stator core of the present invention can be produced by integrally forming the stator core by compression-molding a mixture of amorphous metal powder, soft magnetic powder or amorphous metal powder and soft magnetic powder, Reduction of loss can reduce mold production cost and simplify the manufacturing process.

Further, in the bladelike type motor having the integral type stator core of the present invention, the height of the axial stator core can be reduced by integrally forming the stator core, thereby realizing slimming of the motor. Furthermore, the area is the same, and as the height is reduced, the circumference is reduced, and the coiling loss and the weight of the coil can be reduced.

Further, in the further blotter type motor having the integral type stator core of the present invention, the height of the rotor magnet and the stator core can be designed to be the same, and the motor efficiency can be improved.

In the rotor type motor having the integral type stator core of the present invention, the first coil and the second coil are wound with the integral core portion, and the connecting portion connecting the stator cores having the complicated shapes is formed as the laminated type connecting core portion And by integrally joining the integral core portions to both side surfaces of the laminated connection core portion, it is possible to manufacture the stator core having a complicated shape as a unitary structure.

1 is a cross-sectional view of a motor according to an embodiment of the present invention.
2 is a cross-sectional view of a motor according to another example of the present invention.
3 is a cross-sectional view of a stator according to the present invention.
4 is an exploded perspective view of the stator core according to the present invention.
5 is a plan view of a stator core according to the present invention.
6 is a cross-sectional view of a stator core according to the present invention in which a bobbin is wrapped.
7 is an exploded top view of a stator core according to another example of the present invention.
8 is a process flow chart showing a stator manufacturing process according to the present invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. The sizes and shapes of the components shown in the drawings may be exaggerated for clarity and convenience. In addition, terms defined in consideration of the configuration and operation of the present invention may be changed according to the intention or custom of the user, the operator. Definitions of these terms should be based on the content of this specification.

Referring to FIG. 1, a motor according to an embodiment of the present invention includes a stator 10 having a first coil 16 and a second coil 18 wound therein, a stator 10, And an inner rotor 80 which is disposed at an inner peripheral surface of the stator 10 with a predetermined gap therebetween.

The outer rotor 20 includes a first magnet 22 disposed with a certain gap from the outer surface of the stator 10, a first back yoke 24 disposed on the rear surface of the first magnet 22, And a first rotor support body 26 to which the first back yoke 24 and the first back yoke 24 are fixed.

The inner rotor 80 includes a second magnet 82 disposed with a certain gap from the inner surface of the stator 10, a second back yoke 84 disposed on the back surface of the second magnet 82, And a second rotor support body 86 to which the second back yoke 84 is fixed.

Here, the first rotor support body 26 may be integrally formed by insert molding after annularly arranging the first magnet 22 and the first back yoke 24 in the mold, and the second rotor support body 86 May also be integrally formed by insert molding after the second magnet 82 and the second back yoke 84 are annularly arranged in the mold.

Since the motor of the present invention is a double rotor type, the inner rotor 20 and the outer rotor 80 can be independently driven.

1, the first rotor support body 26 and the second rotor support body 86 may be integrally formed and connected to a single rotation shaft 70. In this case, Such a motor can control the driving force of the motor. That is, when either the outer rotor 20 or the inner rotor 80 is driven, the driving force is small, and when the outer rotor 20 and the inner rotor 80 are simultaneously rotated, the driving force can be increased.

2, the inner rotor 20 and the outer rotor 80 are connected to the first rotary shaft 72 and the second rotary shaft 74, respectively, The rotary shaft 72 and the second rotary shaft 74 can be independently driven.

When the motor according to another example is applied to the automatic washing machine, the first rotor support body 26 is connected to the first rotation shaft 72 connected to the pulsator of the washing machine, and the second rotor shaft 26 connected to the second rotation shaft 74 connected to the washing machine of the washing machine. A support 86 is connected.

The outer rotor 20 and the inner rotor 80 are rotated only when the inner rotor 80 is driven, The pulsator and the washing tub can be rotated at the same time. Accordingly, the pulsator and the washing machine can be driven independently, and various types of washing modes can be realized using the pulsator and the washing machine.

3 to 6, the stator 10 includes a plurality of stator cores 12 arranged in an annular shape, a bobbin 14 as a non-magnetic body wrapped around the outer circumferential surface of the stator core 12, A first coil 16 wound on one side of the stator core 12, a second coil 18 wound on the other side of the stator core 12, and a fixing bracket 60 for fixing the stator core 12 .

Here, since the first driving signal is applied to the first coil 16 and the second driving signal is applied to the second coil 18, when the driving signal is applied only to the first coil 16, the outer rotor 20 And a driving force is applied only to the second coil 18, a rotational force is generated only by the inner rotor 80. When a driving signal is simultaneously applied to the first coil 16 and the second coil 18 A rotational force is generated in the outer rotor 20 and the inner rotor 80.

The stator core 12 includes a first integral type core portion 30 formed integrally with a metal mold by compression molding with an amorphous metal powder and wound around the first coil 16 and a first integral type core portion 30 formed by compression molding with an amorphous metal powder, And a second integral core portion 40 formed by winding the second integral core portion 40 and the second integral core portion 40. The first integral type core portion 30 and the second integral type core portion 40 are press- And the laminated connecting core portion 50 is formed.

The first integral core portion 30 includes a first yoke portion 32 on which the first coil 16 is wound and a second yoke portion 32 formed on one end of the first yoke portion 32 and facing the outer rotor 20 1 flange portion 34 as shown in Fig.

The second integral core portion 40 includes a second yoke portion 42 on which the second coil 18 is wound and a second yoke portion 42 formed on one end of the second yoke portion 42 and facing the inner rotor 80 2 flange portion 44 as shown in Fig.

Here, the first yoke portion 32 and the first flange portion 34 may be manufactured separately and coupled to each other. Likewise, the second yoke portion 42 and the second flange portion 44 may also be separately manufactured and then joined together.

7, press-fit grooves 35, 45 are formed in the first flange portion 34 and the second flange portion 44, and one end of the first yoke portion 32 and the other end portion of the second yoke portion 32, One end of the first yoke portion 42 and the second yoke portion 42 can be press-fitted into the press-fitting grooves 35 and 45 to be assembled with each other, and the first yoke portion 32 and the first flange portion 34, And the support portions 44 can be assembled together by bonding.

The first integral core portion 30 and the second integral core portion 40 may be extrusion-molded in addition to compression molding.

The first integral core portion 30 and the second integral core portion 40 may be formed by mixing and mixing an amorphous metal powder and a binder or mixing a crystalline metal powder and a binder having excellent amorphous metal powder, Can be molded. In this case, when the metal powders are mixed at a predetermined ratio as compared with the case where 100% of the amorphous metal powder is used, the difficulty of high-pressure sintering can be solved and the permeability can be increased.

The first integral core portion 30 and the second integral core portion 40 can be manufactured by compression molding using only the soft magnetic powder.

The first coil 16 and the second coil 18 are wound around the outer circumferential surfaces of the first yoke portion 32 and the second yoke portion 42. At this time, the first yoke portion 32 and the second yoke portion 42 And coil winding grooves 62 and 64 are formed on the upper and lower surfaces. That is, the height H5 of the first yoke portion 32 and the height H1 of the second yoke portion 42 are made smaller, and the upper surface of the first yoke portion 32 and the upper surface of the second yoke portion 42, Is formed in a concave shape so as to be lower in height than the first flange portion (34) and the second flange portion (44) to form the coil reduction grooves (62, 64).

The coil reduction grooves 62 and 64 are formed on the upper surfaces of the first yoke portion 32 and the second yoke portion 42 and have a height H8 higher than the upper surfaces of the flange portion 34 and the second flange portion 44, A first yoke portion 32 and a second yoke portion 42 formed on the lower surfaces of the first yoke portion 32 and the second yoke portion 42 so as to form the first flange portion 34 and the second yoke portion 42, And a second coil reduction groove (64) recessed inward by a height (H9) of the lower surface of the flange portion (44).

By reducing the height of the axial stator core 10 as described above, it is possible to reduce the overall height of the motor, thereby making it possible to reduce the size of the motor and to reduce the peripheral area of the first yoke portion 32 and the second yoke portion 42 When the same performance can be achieved, the coil winding amount can be reduced and the copper loss can be reduced.

The stacked connection core portion 50 is formed with a first press-fit groove 54 in which a first integral yoke portion 30 is press-fitted and a second press-fit groove portion 54 in which a second integral yoke portion 40 is press- A locking protrusion 57 protruding from one side of the connecting portion 52 and a locking protrusion 57 formed in a groove shape on the other side of the connecting portion 52, And an engaging groove 58 to be engaged.

Here, between the laminated connecting core portion 50 and the first integral core portion 30, and between the laminated connecting core portion 50 and the second integral core portion 40, Can also be applied.

A coupling hole 59 is formed at the center of the stacked connection core portion 50 so that the bolt passes through the fixing bracket 60 when the stator core 10 is bolted and fixed.

The stacked connection core portion 50 directly connects between the stator cores 12 arranged in a radial direction so that the divided stator cores 12 can be mutually energized to form a magnetic circuit.

In addition to this connecting structure, the laminated connecting core portion 50 may have pin holes formed at both ends of the connecting portion 52, and the pin member may be inserted between the pin holes of the two stator cores And a method of caulking the stator core using the caulking member in a state in which the stator cores are in contact with each other can also be applied.

Since the laminated connecting core portion 50 is formed by laminating a plurality of pieces of steel, the strength of the steel piece is strong, so that the engaging protrusions 57 are not separated from the connecting portion 52.

However, when the laminated connection core portion 50 is manufactured by compression-molding an amorphous metal powder like the first integral core portion 30 and the second integral core portion 40, the structure of the metal mold is complicated, , The strength is weak, so that the part of the locking protrusion 57 may fall off.

Therefore, in this embodiment, a plurality of stator cores interconnected with each other are fabricated by laminating a plurality of steel pieces having high strength, and a portion where the coil is wound is formed by compression molding with amorphous metal powder, Thereby improving the motor performance.

The stack height H2 of the stacked connection core portion 50 is set to be equal to the height H5 of the yoke portion 32 of the first integral core portion 30 and the height H5 of the yoke portion 42 of the second integral core portion 40 (H1), the stacking height H2 of the stacked connection core portion 50 can be reduced, and manufacturing cost can be reduced.

The height H7 of the first magnet 22 and the height H3 of the second magnet 82 are equal to the height H6 of the first flange portion 34 and the height H4 of the second flange 44, It is possible to increase the motor efficiency while lowering the height of the motor.

As another example, the laminated connection core portion 50 may be formed by laminating a plurality of iron pieces, as well as the first integral type core portion and the second integral type core portion, in addition to the amorphous metal powder, the soft magnetic powder or the amorphous metal powder, The alloy powder mixed with the magnetic powder may be integrally formed by compression molding or extrusion molding.

Next, a method of manufacturing the stator according to the present invention will be described. FIG. 7 is a process flow diagram illustrating a stator manufacturing method according to an embodiment of the present invention.

First, an amorphous metal powder is compression molded to form a first integral core portion 30 and a second integral core portion 40 (S10).

The first integral core portion 30 and the second integral core portion 40 may be formed by mixing and mixing an amorphous metal powder and a binder or mixing a crystalline metal powder and a binder having excellent amorphous metal powder, And can be formed by mixing a binder with a crystalline metal powder having excellent soft magnetic properties.

Then, the laminated connection core portion 50 is manufactured (S20). That is, the first press-fit groove 54, the second press fit groove 56, the engagement protrusion 57, the engagement groove 58 and the through-hole 59 are integrally formed by cutting the steel plate. Then, a plurality of steel plates are laminated. At this time, the lamination height H2 of the laminated connection core portion 50 is equal to the heights H5 and H1 of the yoke portions 32 and 42 of the first integral core portion 30 and the second integral core portion 40 .

The first integral core portion 30 is press-fitted into the first press-fit groove 54 formed on one surface of the laminated connection core portion 50 and the second press-fit groove 50 formed on the other surface of the laminated connection core portion 50 is press- The second integrated-type core portion 40 is press-fitted into the second integrated-type core portion 56 (S30). That is, the end portion of the yoke portion 32 of the first integral-type connecting core portion 30 is fixed by a method of forcibly pressing the first press-fitting groove into the first press-fitting groove 54, and the yoke portion 42 ) Into the second press-fit groove (56).

Then, a bobbin 14 is formed by inserting insulation resin into the outer surfaces of the first integral core portion 30, the second integral core portion 40, and the laminated connection core portion 50 (S40). Here, the outer surface of the first flange portion 34, the outer surface of the second flange portion 44, and the engagement protrusions 57 and the engagement grooves 58 of the laminated connection core portion 50 are made of resin And is exposed to the outside without being wrapped.

Then, the first coil 16 is continuously wound on the outer surface of the first integral core portion 30 and the second coil 18 is continuously wound on the outer surface of the second integral core portion 40 (S50). When the stator core 12 is radially aligned with the engaging grooves 58 of the stator core 12 disposed adjacent to the engaging protrusions 57 of the stator core 12, the assembly of the stator is completed S60).

Next, the manufacturing method of the first integral core portion 30 and the second integral core portion 40 will be described in detail. As an example, the case of using an amorphous metal powder will be described.

The first integral core portion 30 and the second integral core portion 40 of the present invention can be obtained by preparing an amorphous alloy ribbon or strip of an amorphous alloy having a thickness of 30 μm or less by a rapid solidification method (RSP) Followed by pulverization to obtain an amorphous metal powder. The milled amorphous metal powder thus obtained has a size ranging from 1 to 150 mu m.

In this case, the amorphous alloy ribbon may be heat-treated at 400-600 ° C in a nitrogen atmosphere so as to have a nanocrystalline microstructure capable of achieving a high magnetic permeability.

In addition, the amorphous alloy ribbon may be heat-treated in an atmospheric environment at 100-400 ° C to enhance the grinding efficiency.

As the amorphous alloy powder, it is of course possible to use a spherical powder obtained by the atomization method in addition to the pulverization method of the amorphous alloy ribbon.

The amorphous alloy may be, for example, one of an Fe-based, a Co-based, and a Ni-based alloy, and preferably an Fe-based amorphous alloy is inexpensive. The Fe-based amorphous alloy is preferably any one of Fe-Si-B, Fe-Si-Al, Fe-Hf-C, Fe-Cu-Nb-Si- The Co-based amorphous alloy is preferably any one of Co-Fe-Si-B and Co-Fe-Ni-Si-B.

Thereafter, the pulverized amorphous metal powder is classified according to its size and then mixed with a powder particle size distribution having an optimal composition uniformity. In this case, since the pulverized amorphous metal powder is in the form of a plate, the filling density is not optimal when mixed with a binder and formed into a component shape. Accordingly, in the present invention, spherical soft magnetic powder capable of improving magnetic properties, that is, magnetic permeability, is formed by mixing powder particles in a predetermined amount to increase the molding density.

The spherical soft magnetic powder capable of improving the magnetic permeability and filling density can be, for example, one of MPP powder, HighFlux powder, Sendust powder, iron powder, or a mixture thereof.

The binder mixed with the mixed amorphous metal powder may be a thermosetting resin such as water glass, ceramic silicate, epoxy resin, phenol resin, silicone resin or polyimide. In this case, the maximum mixing ratio of the binder is preferably 20 wt%.

In the mixed amorphous metal powder, the binder and the lubricant are added, and the mixture is compression-molded into a desired core or back yoke using a press and a mold. It is preferable that the forming pressure is set to 15-20 ton / cm < 2 > when the press forming is performed by pressing.

Thereafter, the molded core or back yoke is subjected to annealing heat treatment in the range of 300-600 占 폚 in the range of 10-600 min to realize magnetic properties.

When the heat treatment temperature is less than 300 ° C, the heat treatment time is increased and the productivity is lowered. When the heat treatment temperature exceeds 600 ° C, the amorphous magnetic property deteriorates.

Further, the present invention can also be produced by compression molding only soft magnetic powder in addition to amorphous metal powder.

As described above, in the present invention, since the amorphous metal powder or the soft magnetic powder is compression molded to easily form an integral core portion having a complicated shape, the crystalline metal powder having excellent soft magnetic properties is contained in the amorphous alloy powder, It is possible to improve the magnetic permeability and to improve the molding density in compression molding.

The present invention also provides a method of manufacturing an integrated core and a core of a second integrated core by molding using an amorphous metal powder or a soft magnetic powder or by mixing a crystalline metal powder with an amorphous metal powder to form an eddy current loss ) Can be minimized, making it suitable for use as a high-speed rotation motor of 50,000 rpm or more.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is clearly understood that the same is by way of illustration and example only and is not to be construed as limited to the embodiments set forth herein. Various changes and modifications may be made by those skilled in the art.

10: stator 12: stator core
14: bobbin 16: first coil
18: second coil 20: outer rotor
22: first magnet 24: first back yoke
26: first rotor support 30: first integrated core part
32: first yoke portion 34: first flange portion
40: second integral core part 42: second yoke part
44: second flange portion 50; The stacked-
52: connecting portion 54: first press-fit groove
56: second press-fit groove 57:
58: engaging groove 80: inner rotor
82: second magnet 84: second back yoke
86: second rotor support

Claims (14)

1. A stator comprising: a stator core divided into a plurality of parts and arranged in an annular shape; a bobbin wrapped around an outer circumferential surface of the stator core; a first coil wound on one side of the stator core; and a second coil wound on the other side of the stator core An outer rotor disposed at an outer surface of the stator with a predetermined gap therebetween, and an inner rotor disposed at a predetermined gap on an inner surface of the stator,
The stator core includes: a first integral core portion formed integrally with a metal powder and having a first coil wound therein;
A second integral core portion formed integrally with the metal powder and having a second coil wound therein; And
And a laminated connection core portion in which a plurality of iron pieces are stacked and formed and the first integral core portion and the second integral core portion are combined. The method according to claim 1,
Wherein the first integrated core portion includes a first yoke portion around which the first coil is wound and a first flange portion integrally formed at one end of the first yoke portion and disposed to face the outer rotor,
Wherein the second integral core portion includes a second yoke portion around which the second coil is wound and a second flange portion integrally formed at one end of the second yoke portion and disposed to face the inner rotor, Type motor. 3. The method of claim 2,
Wherein the upper and lower surfaces of the first yoke portion and the second yoke portion are formed with a coil reducing groove having a height lower than that of the upper surface and the lower surface of the first flange portion and the second flange portion, Turbo-type motor. The method of claim 3,
Wherein the coil reducing groove has a first coil reducing groove formed on the upper surface of the first yoke portion and the second yoke portion and inwardly inward by a depth H8 as compared with the upper surfaces of the first flange portion and the second flange portion,
And a second coil reduction groove formed on the lower surface of the first yoke portion and the second yoke portion and inwardly inward by a depth H9 of the lower surface of the first flange portion and the second flange portion, Type motor. The method according to claim 1,
Wherein the first integral core portion and the second integral core portion are formed of an alloy powder of a mixture of an amorphous metal powder and a spherical soft magnetic powder. The method according to claim 1,
Wherein the first integral core portion and the second integral core portion are formed of an amorphous metal powder or a soft magnetic powder. 3. The method of claim 2,
Wherein the laminated connection core portion includes a connection portion having a first press-fit groove formed on one surface thereof to press-fit the first integrated-type core portion and a second press-fit groove formed on the other surface thereof,
An engagement protrusion formed on one side surface of the connection portion,
And an engaging groove formed on the other side surface of the connecting portion and engaged with the engaging projection. 8. The method of claim 7,
Wherein the lamination height of the laminated connection core portion is the same as the height of the first yoke portion and the second yoke portion. 3. The method of claim 2,
Wherein the height of the first magnet and the second magnet of the outer rotor and the inner rotor is the same as the height of the first flange and the second flange. The method according to claim 1,
Wherein the first integrated core portion and the second integrated core portion are formed by compression molding or extrusion molding by any one of an amorphous metal powder, a soft magnetic powder or an alloy powder obtained by mixing an amorphous metal powder and a spherical soft magnetic powder. A further blotter type motor having a stator core. The method according to claim 1,
Wherein the first integral core portion and the laminated connection core portion are bonded to each other by bonding, and between the second integral core portion and the laminated connection core portion are bonded to each other by bonding. 1. A stator comprising: a stator core divided into a plurality of parts and arranged in an annular shape; a bobbin wrapped around an outer circumferential surface of the stator core; a first coil wound on one side of the stator core; and a second coil wound on the other side of the stator core An outer rotor disposed at an outer surface of the stator with a predetermined gap therebetween, and an inner rotor disposed at a predetermined gap on an inner surface of the stator,
The stator core includes: a first integral core portion formed integrally with a metal powder and having a first coil wound therein;
A second integral core portion formed integrally with the metal powder and having a second coil wound therein; And
And a laminated connection core portion in which a plurality of iron pieces are stacked and formed and the first integral core portion and the second integral core portion are joined,
The first integrated core portion and the second integrated core portion may include a first yoke portion and a second yoke portion around which a coil is wound;
Type motor having an integral stator core including a first flange portion and a second flange portion which are separately manufactured from the first yoke portion and the second yoke portion and to which the first yoke portion and the second yoke portion are coupled. 13. The method of claim 12,
Wherein the first flange portion and the second flange portion are formed with press-fit grooves for press-fitting one end of the first yoke portion and the second yoke portion. 1. A stator comprising: a stator core divided into a plurality of parts and arranged in an annular shape; a bobbin wrapped around an outer circumferential surface of the stator core; a first coil wound on one side of the stator core; and a second coil wound on the other side of the stator core An outer rotor disposed at an outer surface of the stator with a predetermined gap therebetween, and an inner rotor disposed at a predetermined gap on an inner surface of the stator,
The stator core includes: a first integral core portion formed integrally with a metal powder and having a first coil wound therein;
A second integral core part formed integrally with the metal powder and wound with a coil; And
Type motor having an integral stator core including the first integral core portion and the second integral-type core portion joined together, and integrally formed with the metal powder to form a connecting core portion connecting between the stator cores.

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