(12) United States Patent
`Suzuki et al.
`
`I IIIII IIIIIIII Ill lllll lllll lllll lllll lllll lllll lllll lllll 111111111111111111
`US006177751Bl
`US 6,177,751 Bl
`Jan.23,2001
`
`(10) Patent No.:
`(45) Date of Patent:
`
`(54) ROTARY ELECTRIC MACHINE AND
`BOBBIN THEREOF
`
`(75)
`
`Inventors: Yuzuru Suzuki; Sakae Fujitani, both
`of Shizuoka-ken; Kunitake Matsushita,
`Shizuoka; Takayuki Yamawaki,
`Shizuoka; Hiroshi Sano, Shizuoka;
`Kazuo Muramatsu, Shizuoka; Taichi
`Nishio, Shizuoka, all of (JP)
`
`(73) Assignee: Minebea Co., Ltd., Nagano-Ken (JP)
`
`4,795,933 * 1/1989 Sakai .................................... 310/269
`
`FOREIGN PATENT DOCUMENTS
`359070160A * 4/1984 (JP) .
`403155347A * 7/1991 (JP).
`
`* cited by examiner
`
`Primary Examiner-Nestor Ramirez
`Assistant Examiner-Guillermo Perez
`(74) Attorney, Agent, or Firm-Faye, Sharpe, Fagan,
`Minnich & McKee, LLP
`
`( *) Notice:
`
`Under 35 U.S.C. 154(b), the term of this
`patent shall be extended for O days.
`
`(57)
`
`ABSTRACT
`
`(21) Appl. No.: 09/377,787
`
`(22) Filed:
`
`Aug. 20, 1999
`
`(30)
`
`Foreign Application Priority Data
`
`Aug. 21, 1998
`
`(JP) ................................................. 10-235507
`
`(51)
`
`Int. Cl.7 ............................ H02K 1/24; H02K 15/00;
`H02K 1/00; H02K 1/18; H02K 1/12
`(52) U.S. Cl. ............................ 310/269; 310/42; 310/194;
`310/218; 310/259
`(58) Field of Search ..................................... 310/269, 264,
`310/45, 214, 42, 194, 218, 259
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`2,655,613 * 10/1953 Weiseman ............................ 310/264
`2,691,113 * 10/1954 Ordas ................................... 310/214
`2,870,357 * 1/1959 Vandenberg et al. ................ 310/269
`
`The object of the present invention is to provide a rotary
`electric machine that provides bobbins with good assem(cid:173)
`bling efficiency and allows no dislocation of the stator. A
`motor 2 comprises a case 4, a stator 6 secured inside the case
`4, a rotor 10 formed into one piece with a rotating shaft 8.
`The stator 6 comprises stator yokes 32 and the stator yokes
`are secured in a radial manner in the case 4. Furthermore,
`resin 58 is filled in between the stator 6 and the case 4 with
`a space for the rotor being left. The stator yokes 32 comprise
`a salient pole 34, a bobbin 36 for holding the salient pole 34,
`and a magnetic wire 38 wound around the bobbin 36. A
`collar 39b of the bobbin 36 is formed so as to contact each
`other with notches 3 formed on two, upper and lower edge
`portions. Accordingly, combining two bobbins 36, 36 allows
`through-holes 5 penetrating the collar 39b thereof. This
`allows the stator to be firmly assembled, provides good
`assembling workability, and allows no dislocation owing to
`resin flowing when the resin is injected.
`
`14 Claims, 7 Drawing Sheets
`
`39b
`38
`39a
`5
`
`36
`
`34
`
`6
`
`I
`
`39b
`38
`/32
`
`39a
`
`34
`
`36
`
`36
`
`Mitsuba - 1002
`Page 1 of 11
`
`

`

`U.S. Patent
`
`Jan.23,2001
`
`Sheet 1 of 7
`
`US 6,177,751 Bl
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`Mitsuba - 1002
`Page 2 of 11
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`

`

`U.S. Patent
`
`Jan. 23, 2001
`
`Sheet 2 of 7
`
`US 6,177,751 Bl
`
`FIG. 2
`
`58
`
`4
`
`8
`
`58
`
`10
`
`Mitsuba - 1002
`Page 3 of 11
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`

`

`U.S. Patent
`
`Jan. 23, 2001
`
`Sheet 3 of 7
`
`US 6,177,751 Bl
`
`FIG. 3
`
`39b
`38
`39a
`5
`
`36
`
`5
`
`36
`
`6
`
`I
`
`39b
`38
`
`/32
`
`39a
`
`--~34
`
`36
`
`36
`
`34
`
`Mitsuba - 1002
`Page 4 of 11
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`

`

`Jan. 23, 2001
`
`Sheet 4 of 7
`
`US 6,177,751 Bl
`
`39b
`
`·~-39a
`
`U.S. Patent
`FIG. 4
`38
`
`36
`
`34
`
`I
`
`l Jl,
`40 _/ 40
`
`/
`
`39a
`
`36-
`
`37
`
`FIG. 5
`
`34
`
`40
`
`Mitsuba - 1002
`Page 5 of 11
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`

`

`U.S. Patent
`
`Jan. 23, 2001
`
`Sheet 5 of 7
`
`US 6,177,751 Bl
`
`FIG. 6
`
`36
`
`39b
`
`/
`
`/
`
`/
`
`5
`
`FIG. 7
`
`39b
`
`38
`39a
`
`32~
`
`Ill
`
`36
`
`34
`
`39b
`~36
`
`39b
`38
`
`~32
`
`39a
`
`36
`34
`
`Mitsuba - 1002
`Page 6 of 11
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`

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`U.S. Patent
`
`Jan. 23, 2001
`
`Sheet 6 of 7
`
`US 6,177,751 Bl
`
`FIG. 8
`
`36 39b
`
`\
`
`43
`"
`
`\
`
`FIG. 9
`
`36
`
`39b
`
`/
`
`/
`
`/
`
`5
`
`41
`
`I
`I
`
`39b
`--36
`
`36
`
`Mitsuba - 1002
`Page 7 of 11
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`

`

`U.S. Patent
`
`Jan. 23, 2001
`
`Sheet 7 of 7
`
`US 6,177,751 Bl
`
`FIG. 10
`
`36'
`
`39'
`
`36'
`
`39'
`
`34
`
`10'
`
`4
`
`6
`
`39'
`
`36'
`
`32
`
`Mitsuba - 1002
`Page 8 of 11
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`

`

`US 6,177,751 Bl
`
`1
`ROTARY ELECTRIC MACHINE AND
`BOBBIN THEREOF
`
`BACKGROUND OF THE INVENTION
`
`10
`
`2
`arranged, and a rotor having a permanent magnet is rotatably
`provided against the salient pole of the stator yoke, both
`ends of the stator yoke bobbin are formed to contact with
`each other, whereby stator yokes can be arranged with
`5 accuracy by allowing an edge to contact with another edge
`and can be positively secured at predetermined positions as
`well.
`Furthermore, notches are formed at the bobbin, for
`example, at contact portions on the edge of the bobbin, and
`through-holes are formed which penetrate the stator yoke.
`Accordingly, injecting resin in between the stator yokes and
`the case causes the resin to flow through the through-holes
`out to the front and rear surfaces of the bobbin, whereby the
`stator yokes are secured into one piece with the resin, and
`15 thus assembly work can be simplified and the mounting
`accuracy of the motor can be improved.
`The through-holes may be not only notches or the like
`provided on the edge of the bobbin, but also holes that
`penetrate the bobbin itself.
`Furthermore, the stator yoke may be provided, on the
`edge thereof, with a projection and depression so that other
`bobbins are mated with each other. This allows the stator
`yoke to be more secure when stator yokes are combined, and
`allows the securing force to be increased as well. The mating
`portion may have at least, but is not necessarily limited to,
`a projection and a depression that allows for no displace(cid:173)
`ment between bobbins; the mating portion may be of a
`slidable type for assembly, may be provided with a pin and
`30 a hole for insertion, or may be mated with another one by
`bonding or adhesion.
`Furthermore, such a rotary electric machine is possible in
`that the stator yoke may be provided on, but is not limited
`to, the outer circumference; the stator yoke may be arranged
`inside and a rotor outside.
`
`20
`
`1. Field of the Invention
`The present invention relates to a miniature cylindrical
`radial-gap type rotary electric machine having improved
`mounting accuracy of stator yokes and handling such as
`assembly thereof and, more particularly, to a bobbin that
`allows positive positioning between the stator yokes and a
`rotary electric machine adopting the bobbin.
`2. Description of the Prior Arts
`Generally, an inner rotor type brushless DC motor has
`stator yokes arranged on the inside of a case of the motor and
`a rotor rotatably arranged at the center portion of the stator
`yokes wherein the stator yokes are excited to rotatably drive
`the rotor. A stator yoke comprises a salient pole composed
`of a plurality of laminated thin plates which is fitted into a
`bobbin and magnet wires wound around the bobbin. The
`stator yokes, thus fabricated are predetermined positions
`inside the case of the motor.
`The inventor of the present application proposed in Japa(cid:173)
`nese Patent Application No. 178687/1997 a rotary electric
`machine wherein resin is injected in between a case of the 25
`motor and a stator portion to form them into one piece. This
`proposal brings such advantages that filling of the resin
`allows the stator to be secured to the case with the result that
`assembling accuracy is improved and durability is increased.
`However, in the above proposed motor a plurality of stator
`yokes must be secured to the inside of the case with
`accuracy, thus resulting in much labor and time for the
`assembly. For example, when a plurality of stator yokes are
`mounted on the inner surface of the case, if the center of the
`assembly is dislocated from the center of revolution of the 35
`rotor, or there is a variation of a distance between the stator
`yokes thus mounted, then torque ripple or cogging torque
`shall be increased with the result that the performance of the
`motor will be lowered.
`Furthermore, in the rotary electric machine above(cid:173)
`mentioned wherein resin is injected in the case of the motor,
`the stator yokes must be positively held at predetermined
`positions until the resin completely solidifys. In this case,
`there are problems in that weak holding of the stator yokes
`causes displacement thereof or dislocation of the center
`thereof thereby reducing the efficiency of the motor.
`Furthermore, if the stator yokes are arranged so closely
`with each other at the edge portions thereof, resin flow will
`be blocked thus preventing resin from being filled in the 50
`whole stator yokes from the front to the rear surfaces
`thereof.
`
`45
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`FIG. 1 is a longitudinal sectional view showing an
`embodiment of a motor as an example of a rotary electric
`40 machine according to the present invention;
`FIG. 2 is a cross-sectional view of the motor shown in
`FIG. 1;
`FIG. 3 is a perspective view showing an embodiment of
`a stator of the motor shown in FIG. 1;
`FIG. 4 is a perspective view showing an embodiment of
`a stator yoke of the stator shown in FIG. 3;
`FIG. 5 is a perspective view showing a salient pole and a
`bobbin of the stator shown in FIG. 3;
`FIG. 6 is a view showing an embodiment of a joint portion
`of the stator yokes;
`FIG. 7 is a view showing the stator yokes having the joint
`portion shown in FIG. 6;
`FIG. 8 is a view showing another embodiment of a joint
`portion of the stator yokes;
`FIG. 9 a view showing further embodiment of a joint
`portion of the stator yokes; and
`FIG. 10 is a view showing another embodiment of a motor
`60 as an example of a rotary electric machine according to the
`present invention.
`
`SUMMARY OF THE INVENTION
`
`55
`
`It is an object of the present invention to solve the
`foregoing problems and provide a rotary electric machine
`wherein stator yokes are positively positioned and secured
`so that smootly flow of resin is improved when the resin is
`filled in the armature portion including the case, and good
`durability is provided.
`According to the present invention, a rotary electric
`machine is constituted as mentioned below in order to solve
`the foregoing problems.
`That is, according to the present invention, in a cylindrical
`radial-gap rotary electric machine wherein a salient pole is 65
`inserted into the center of a bobbin, stator yokes in which
`magnetic wires are wound around said bobbins are radially
`
`DETAILED DESCRIPTION OF THE
`PREFERRED EMBODIMENTS
`The present invention will now be explained below by
`reference to the drawings by taking a motor as an example
`of a rotary electric machine according to the invention.
`
`Mitsuba - 1002
`Page 9 of 11
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`

`

`US 6,177,751 Bl
`
`25
`
`3
`FIG. 1 shows a longitudinal section of a motor 2, and FIG.
`2 shows a cross section of the motor 2. The motor 2 is a
`3-phase inner rotor type brushless DC motor having six
`salient poles and eight rotor field poles. The motor 2
`comprises a case 4, a stator 6 secured inside the case 4, and
`a rotor 10 built into one piece with a rotary shaft 8.
`The case 4 is made of metal, has an approximately
`cylindrical shape, and is provided with flanges 12 and 13 on
`both ends thereof. The flanges 12 and 13 are provided with
`bearings 20 and 21. These bearings 20 and 21 rotatably
`support the rotary shaft 8.
`The rotor 10 comprises the rotary shaft 8, a rotor magnet
`with eight rotor field poles, and a sleeve, and is rotatably
`supported by the bearings 20 and 21 as mentioned above.
`Furthermore, the rotor 10 is provided with a spring holder 25 15
`and a spring 23, whereby the rotor 10 is adequately posi(cid:173)
`tioned in the axial direction thereof, and the pre-load onto
`the bearing 20 is adequately set.
`As shown in FIGS. 2 and 3, the stator 6 comprises six
`stator yokes 32 and is secured radially inside the case 4. A
`stator yoke 32 is shown in FIG. 4, wherein each stator yoke
`32 comprises a salient pole 34, a bobbin 36 for supporting
`the salient pole 34, and a magnet wire 38 wound around the
`bobbin 36.
`As shown in FIG. 5, the salient pole 34 comprises nine
`pieces of electromagnetic steel plates, each having a thick(cid:173)
`ness of 0.35 mm, punched into a shape of a letter T and
`laminated in parallel to the shaft. The narrowly formed
`portion of the salient pole 34 of T shape is inserted into a 30
`rectangular hole 37 of the bobbin 36, while the elongated
`portion is so arranged as to project slightly from the bobbin
`36 toward the rotary shaft 8. The salient pole 34 may be
`laminated in the axial direction so as to be inserted into the
`rectangular hole 37.
`The bobbin 36 which is made of resin, has collars 39a and
`39b and a rectangular hole 37, and is provided with a magnet
`wire 38 wound around the outer circumference of the
`rectangular hole 37. The bobbin 36 is provided on the lower
`end thereof with terminals 40 in which the wound magnetic 40
`wire 38 is tied up at the end thereof. The magnet wire 38 is
`tied up at the terminals 40 and then soldered.
`Furthermore, the collar 39b of the bobbin 36 is provided
`with notches 3 along the direction of insertion of the salient
`pole 34. As shown in FIG. 4, two notches 3 are provided on
`the upper and lower portions on each edge of the bobbin 36,
`respectively in FIG. 3. Combination of two bobbins 36
`shown in FIG. 3 provides a through-hole 5 of the collar 39b.
`Thus, when six stator yokes 32 are arranged as shown in
`FIG. 3, the salient poles 34 of the coil will face the rotor 10
`via a small air gap, if the rotor 10 is inserted, and through(cid:173)
`holes 5 will be provided at two portions, the upper and lower
`portions, on each assembled portion. The stator thus fabri(cid:173)
`cated is arranged on the inner face of the case 4 of the motor
`2 and secured there to with resin 58.
`Now, injection of the resin 58 will be explained below.
`Mold resin is injected inside the case 4 of the motor 2 after
`the stator 6 has been arranged at the predetermined position.
`As shown in FIG. 2, the resin 58 is filled in between the
`stator 6 and the case 4, leaving a space at the center for
`inserting the rotor 10. The resin 58 is also filled in between
`the stator yokes 32 and towards the side of the rotor 10
`through the through-holes 5.
`As shown in FIG. 1, the terminal 40 in which the magnet
`wire 38 is tied up is connected to a printed circuit board 50
`on which electric circuits and electronic parts are mounted.
`
`4
`The printed circuit board 50 is arranged in an electrically
`insulated condition on an end of the case 4 approximately in
`parallel to the flange 13. The printed circuit board 50
`includes hall sensors 52 (three in this arrangement) for
`5 detecting rotor field poles of the rotor 10 as well as electric
`circuits, and is connected to a connector 53 for external
`connection use. With this arrangement information on the
`position of the rotor 10 in provided via the connector 53 and
`the rotor 10 in driven by exciting each phase in accordance
`10 with such position information from the hall sensors 52. A
`pin holder 57 made of resin is provided for protection of the
`connector 53.
`Accordingly, in the motor 2, the edge portions of the
`bobbins 36 of the stator yokes 32, provided with the notches
`3, engage with each other to form through-holes 5 penetrat(cid:173)
`ing from the front surface to the rear surface by combination
`of the bobbins. Such arrangement provides accurate cou(cid:173)
`pling of the stator yokes 32. Furthermore, the resin 58
`injected after the stator yokes 32 have been accommodated
`20 in the case 4 will be filled in toward the side of the rotor 10
`though the through-holes 5. This allows complete filling of
`the resin 58 even at a low injection pressure, and thus allows
`shortening time of filling of the resin. Additionally secure
`fixing of the stator yokes 32 can be attained.
`Through-holes 5 may be provided not on the edges of the
`bobbin 36, but may be formed through the collar 39b itself.
`Another embodiment of a rotary electric machine is
`shown below.
`In the embodiment shown in FIGS. 6 and 7, the bobbin 36
`has a projection and a depression on both edge portions of
`the collar 39 thereof along a longitudinal direction thereof in
`a mirror image relationship. As shown in FIG. 6, when two
`bobbins 36 are brought into engagement with each other, the
`35 projection and depression of one bobbin 36 engages those of
`the other bobbin 36 to secured with each other.
`Accordingly, bobbins 36 can be easily handled before the
`stator 6 is accommodated in the case 4 and can be secured
`when accommodated in the case 4, and, moreover, will never
`cause dislocation to occur when the resin 58 is injected.
`Furthermore, as the through-holes 5 are formed between the
`stator yokes 32 connected, if the resin 58 is injected after the
`stator 6 has been accommodated in the case 4, then the resin
`58 will penetrate through the through-holes 5 to one side and
`45 the other side of the bobbins 36, whereby the stator 6 can be
`secured to the case 4.
`As shown in FIG. 8, the collar 39b of a first bobbin 36
`may be provided with a pin 41, and the collar 39b of another
`bobbin 36 to be coupled to the first bobbin may be provided
`50 with a hole 43 which can fit the pin 41, so that these two
`bobbins are coupled. Furthermore, as shown in FIG. 9, a slot
`45 may be adopted for coupling.
`A third embodiment will now be explained by reference
`to FIG. 10. FIG. 10 shows an outer rotor type rotary electric
`55 machine having the rotor 10 arranged on the outer circum(cid:173)
`ference. In this embodiment, the contact portions of a stator
`6 arranged at the center are formed so as to secure surface
`contact with each other, thereby providing positive securing
`of the contact portions of the stator 6. In addition, as
`60 mentioned above, the collar 39' of the bobbin 36' may be
`provided with through-holes for allowing resin to pass
`through or a shape for engaging each other.
`In the foregoing embodiments explanation is given to a
`motor as an example, however, the stator structure of the
`65 rotary electric machine according to the present invention
`and the rotary electric machine are not limited to only a
`motor. In addition, the salient pole 34 may not be laminated
`
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`Page 10 of 11
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`

`US 6,177,751 Bl
`
`20
`
`5
`in parallel to the axial direction of the rotary shaft 8 but may
`be laminated sequentially in the axial direction in the
`conventional manner.
`According to the present invention, the contact portions of
`the stator yokes are contacted directly with each other so that 5
`handling and assembly of the stator will be easy, and secure
`fixing in the case will be expected.
`Furthermore, through-holes are formed at the stator
`yokes, so that when resin is filled in between the stator and
`the case, there will be easy flow of resin through the 10
`through-holes to one side and the other side of the collar
`thereby providing secure fixing of the stator by means of the
`resm.
`Still furthermore, the stator yokes is provided on the 15
`contact portion with an engagement portion to allow stators
`to engage each other, whereby a brushless DC motor can be
`provided allows easy handling in assembly and no disloca(cid:173)
`tion due to the injection of resin, and has a long life and high
`reliability.
`What is claimed is:
`1. A cylindrical radial-gap rotary electric machine, com(cid:173)
`prising:
`a case;
`a plurality of stator yokes radially arranged in the case, 25
`each of the stator yokes having a respective salient
`pole;
`a resin material located between the case and the stator
`yokes for securing the stator yokes to the case;
`a plurality of bobbins, respective magnetic wires being 30
`wound around each of the bobbins, a respective one of
`the bobbins being arranged around a corresponding one
`of the salient poles;
`a rotor, rotatably arranged with respect to each of the 35
`stator yokes, including a permanent magnet opposing
`each of the respective salient poles of said stator yokes,
`substantially entire portions of a plurality of edges of
`respective ones of the bobbins contacting substantially
`entire portions of respective edges of adjacent bobbins; 40
`and
`through-holes formed in the bobbins, the resin flowing
`through the through-holes and substantially filling a
`space between the case and the stator yokes.
`2. The rotary electric machine according to claim 1, 45
`wherein the resin flows to a side of the rotor.
`3. The rotary electric machine according to claim 1,
`wherein each of the bobbins includes edges shaped for
`engagingly contacting the edges of the adjacent bobbins.
`4. The rotary electric machine according to claim 1, 50
`further including:
`through-holes formed along the edges of the bobbins, the
`resin flowing through the through-holes.
`5. The rotary electric machine according to claim 1,
`wherein the contacting edges of the adjacent bobbins couple 55
`each of the stator yokes to an adjacent stator yoke, each of
`the coupled stator yokes being at a predetermined position
`with respect to the other stator yokes.
`6. The rotary electric machine according to claim 1,
`wherein the edges of each of the bobbins are shaped in a 60
`mirror image with respect to the edges of the other bobbins.
`7. The rotary electric machine according to claim 1,
`wherein the stator yokes surround the rotor.
`8. The rotary electric machine according to claim 1,
`wherein the rotor surrounds the stator yokes.
`
`6
`9. A method for positioning bobbins between respective
`stator yokes and a machine case, comprising:
`radially arranging the stator yokes in the machine case,
`each of the stator yokes having a respective salient
`pole;
`passing a resin material through through-holes formed in
`the bobbins;
`substantially filling a space between the machine case and
`the stator yokes with the resin for securing the stator
`yokes to the machine case;
`winding respective magnetic wires around the bobbins;
`arranging the bobbins around the salient poles; and
`positioning a rotor in a relationship with respect to the
`stator yokes such that a permanent magnet attached to
`the rotor opposes each of the salient poles, substantially
`entire portions of a plurality of edges of each of the
`bobbins contacting substantially entire portions of
`respective edges of adjacent bobbins.
`10. The method for positioning bobbins between respec(cid:173)
`tive stator yokes and a machine case according to claim 9,
`wherein the filling step includes:
`passing the resin to a side of the rotor.
`11. The method for positioning bobbins between respec(cid:173)
`tive stator yokes and a machine case according to claim 9,
`wherein the passing step includes:
`passing the resin through through-holes along edges of the
`bobbins.
`12. The method for positioning bobbins between respec(cid:173)
`tive stator yokes and a machine case according to claim 9,
`wherein the step of arranging the bobbins includes:
`engagingly contacting the edges of the bobbins with the
`edges of the adjacent bobbins.
`13. A cylindrical radial-gap rotary electric machine, com(cid:173)
`prising:
`a case;
`a plurality of stator yokes radially arranged in respective
`predetermined positions within the case and secured to
`the case by a resin material between the case and the
`stator yokes;
`a plurality of salients poles, each of the salient poles being
`associated with a respective stator yoke;
`a plurality of bobbins, respective magnetic wires being
`wound around each of the bobbins, a respective one of
`the bobbins being arranged around a corresponding one
`of the salient poles;
`through-holes formed in the bobbins, the resin flowing
`through the through-holes and substantially filling a
`void between the case and the stator yokes; and
`a rotor, rotatably arranged with respect to each of the
`stator yokes, including a permanent magnet opposing
`each of the respective salient poles of said stator yokes,
`the predetermined positions of the stator yokes being
`achieved when substantially entire portions of a plu(cid:173)
`rality of edges of respective ones of the bobbins contact
`substantially entire portions of respective edges of
`adjacent bobbins.
`14. The cylindrical radial-gap rotary electric machine
`according to claim 13, wherein the resin flows to a side of
`the rotor.
`
`* * * * *
`
`Mitsuba - 1002
`Page 11 of 11
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