U.S. patent application number 12/081185 was filed with the patent office on 2008-09-04 for motor.
Invention is credited to Sean Chang, Lee-Long Chen, Shih-Ming Huang, Wen-Shi Huang.
Application Number | 20080213104 12/081185 |
Document ID | / |
Family ID | 34132836 |
Filed Date | 2008-09-04 |
United States Patent
Application |
20080213104 |
Kind Code |
A1 |
Chen; Lee-Long ; et
al. |
September 4, 2008 |
Motor
Abstract
A motor includes a stator, a rotor, a top magnetic structure,
and a bottom magnetic structure. The stator is disposed in a frame.
The rotor is also disposed in the frame, corresponding to the
stator. The rotor includes a shaft extending axially from the
rotor. The bottom magnetic structure is at the bottom of the frame.
The top magnetic structure is on the top of the frame. The top and
bottom magnetic structures are opposite to each other in an axial
direction. Magnetic attraction generated between the first magnetic
structure and the shaft, and the second magnetic structure and the
shaft positions the shaft therebetween such that the first magnetic
structure, the second magnetic structure, and the shaft are
coaxially aligned.
Inventors: |
Chen; Lee-Long; (Taoyuan
Hsien, TW) ; Huang; Shih-Ming; (Taoyuan Hsien,
TW) ; Chang; Sean; (Taoyuan Hsien, TW) ;
Huang; Wen-Shi; (Taoyuan Hsien, TW) |
Correspondence
Address: |
BIRCH STEWART KOLASCH & BIRCH
PO BOX 747
FALLS CHURCH
VA
22040-0747
US
|
Family ID: |
34132836 |
Appl. No.: |
12/081185 |
Filed: |
April 11, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10878114 |
Jun 29, 2004 |
|
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12081185 |
|
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Current U.S.
Class: |
417/354 |
Current CPC
Class: |
F04D 25/062 20130101;
F04D 29/051 20130101; F16C 2360/46 20130101; H02K 7/14 20130101;
H02K 7/09 20130101; F16C 39/063 20130101; F16C 17/08 20130101 |
Class at
Publication: |
417/354 |
International
Class: |
F04B 17/00 20060101
F04B017/00 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 15, 2003 |
TW |
92122447 |
Claims
1. A fan assembly comprising: a stator disposed in a frame; a rotor
disposed in the frame and corresponding to the stator and
comprising a shaft without any sleeve, hydrodynamic, ceramic or
ball supports; at least one first magnetic structure disposed at a
bottom of the frame; and at least one second magnetic structure
disposed in the frame; wherein magnetic interaction generated
between the first magnetic structure and the shaft, and the second
magnetic structure and the shaft positions the shaft therebetween
such that the first magnetic structure, the second magnetic
structure, and the shaft are coaxially aligned.
2. The fan assembly as claimed in claim 1, wherein the first
magnetic structure and the second magnetic structure disposed
opposite to each other in an axial direction.
3. The fan assembly as claimed in claim 1, wherein the shaft
directly contacts or magnetically attracts with the first magnetic
structure or/and the second magnetic structure.
4. The fan assembly as claimed in claim 1, further comprising at
least one wear-resistant structure disposed between the shaft and
the first magnetic structure, and the shaft and the second magnetic
structure.
5. The fan assembly as claimed in claim 4, wherein the shaft
directly contacts the wear-resistant structure at a contact
point.
6. The fan assembly as claimed in claim 1, wherein a polarity of a
side of the first magnetic structure facing the second magnetic
structure is opposite to a polarity of a side of the second
magnetic structure facing the first magnetic structure.
7. The fan assembly as claimed in claim 1, wherein the rotor
comprises at least one third magnetic structure with a first
magnetic central plane, and the stator comprises at least one
permeable structure with a second magnetic central plane
corresponding to the third magnetic structure, wherein the first
magnetic central plane is disposed slightly above or below the
second magnetic central plane in an axial direction of the
shaft.
8. The fan assembly as claimed in claim 1, wherein the stator
further comprises an opening defined at the center thereof with the
shaft extended therein, and a protective structure disposed on a
sidewall of the opening without contacting the shaft.
9. The fan assembly as claimed in claim 8, wherein the protective
structure is made of plastic, flexible material or vibration
absorbing material.
10. The fan assembly as claimed in claim 1, wherein an end surface
of the shaft has a flat, curved, pointed, concave or convex shape,
and the first magnetic structure and the second magnetic structure
have end portions, each of the end portions, facing the shaft, with
a curved, pointed, concave or convex shape corresponding to that of
the end surface of the shaft.
11. The fan assembly as claimed in claim 1, wherein when the shaft
contacts the first and the second magnetic structures, the shape of
the end surface of the shaft corresponds to the end portions of the
first magnetic structure, the second magnetic structure or
both.
12. The fan assembly as claimed in claim 4, wherein an end surface
of the shaft has a flat, curved, pointed, concave or convex shape,
and the wear-resistant structure has an end, facing the shaft, with
a flat, curved, pointed, concave or convex shape corresponding to
that of the end surface of the shaft.
13. The fan assembly as claimed in claim 4, wherein when the shaft
contacts the wear-resistant structure at a contact point, the shape
of the end surface of the shaft corresponds to the shape of the end
of the wear-resistance.
14. The fan assembly as claimed in claim 1, wherein the first or
the second magnetic structures is a permanent magnet, a plastic
magnet or an electromagnet.
15. The fan assembly as claimed in claim 1, wherein the frame
comprises an upper cover and a lower cover corresponding to each
other and connected by fitting, engaging, gluing, locking or
connecting via a cushion device.
16. A fan assembly comprising: a base; a stator disposed on the
base; a rotor coupled to the stator and having a shaft; a first
magnetic structure disposed at a bottom of the base and positioned
under the shaft to generate a magnetic interaction between the
shaft and the first magnetic structure.
17. The fan assembly as claimed in claim 16, further comprising a
second magnetic structure disposed at a top of the base, and a
third magnetic structure disposed inside a hub of the rotor to
generate a magnetic interaction between the second and third
magnetic structures.
18. The fan assembly as claimed in claim 16, further comprising a
protective structure disposed in an axial tube of the base and
around the shaft.
19. The fan assembly as claimed in claim 16, further comprising a
wear-resistant structure disposed between an end of the shaft and
the first magnetic structure.
20. The fan assembly as claimed in claim 19, wherein the end of the
shaft has a shape corresponding to that of the first magnetic
structure or the wear-resistant structure so as to form a point
contact therebetween.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This Non-provisional application is a Continuation
Application claiming the benefit of U.S. Non-provisional
Application No. 10/878,114 filed on Jun. 29, 2004, and for which
priority is claimed under 35 U.S.C. .sctn. 120; and this
application claims priority of Application No. 092122447 filed in
Taiwan Aug. 15, 2003 under 35 U.S.C. .sctn. 119; the entire
contents of all are hereby incorporated herein by reference.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates to a motor, and in particular
to a high power motor not utilizing bearings.
[0004] 2. Description of the Related Art
[0005] A conventional motor comprises a shaft, a rotor, and a
bearing. The rotor is disposed on the shaft and supported by the
bearing, enabling the rotor to rotate smoothly.
[0006] Mechanical components reducing friction and bearing loads in
rotary and linear drives include ball and roller bearings, sleeve
bushings, dynamic bearings, magnetic bearings, and other
configurations.
[0007] A ball bearing comprises an outer ring, an inner ring, and a
plurality of metal balls disposed therebetween. The ball bearing is
actuated by rolling of the metal balls. Only one contact point
between the metal balls and the inner or outer ring allows easy
acceleration of the motor. The structure of the ball bearing,
however, is weak and susceptible to impact. In addition, when the
motor with the ball bearing is operated, the balls roll at high
speeds, resulting in producing high noise level. The structural
interface between the balls and the inner and outer rings requires
a high degree of accuracy, thus increasing manufacturing costs.
[0008] A sleeve bearing is formed by mixing and sintering bronze
powder, iron powder, nickel powder, lead powder and other metal
powders. Lubricant is applied into the pores of the bearing. The
sleeve bearing, when disposed in a motor, is fastened in the
central position of the stator. The shaft of the rotor is disposed
in the bearing such that a gap is maintained between the bearing
and the shaft. When the motor is operated, the lubricant exudes
from the bearing such that the rotor rotates in the lubricant. This
type of bearing can sustain higher impact than the ball bearing,
and manufacturing costs are also reduced. In a motor utilizing the
sleeve bearing, however, the lubricant evaporates into gaseous
phase as the bearing is operated over long periods. As a result,
the shaft directly contacts the bearing such that friction is
produced therebetween. Furthermore, nitrides can possibly form at
the ends of the bearing, causing damage and increasing noise level.
In addition, dust in the air may be drawn into the center of the
motor during operation, contaminating the lubricant surrounding the
bearing, increasing noise level and occluding moving parts.
Furthermore, since the gap between the bearing and the shaft is
small, the efficiency in starting the motor is reduced.
[0009] A dynamic bearing is a variation of the sleeve bearing. This
type of bearing comprises an inner wall with two annular arrays of
V-shaped grooves formed therein. During operation, air. and
lubricant are impelled toward the pointed ends of the grooves
forming two oil-gas cushions to support the shaft. In a motor with
this type of bearing, the oil-gas cushion, formed at the pointed
end of the V-shaped groove, is unable to be dispersed or
evaporated. Formation of the groove on the inner side of the
dynamic bearing, however, requires precise manufacturing.
Furthermore, the gap between the shaft and the bearing must be
accurately maintained. Thus, the manufacturing cost is higher than
other types of bearings. Moreover, when the motor operates at low
speed, the oil-gas cushion is not formed. Thus, the dynamic effect
is not achieved at low speeds, such that performance of the dynamic
bearing is substantially the same as a sleeve bearing.
[0010] A magnetic bearing has a plurality of N-S (north-south)
magnetic poles formed on the shaft. The bearing corresponding to
the shaft has the same N-S poles formed thereon. During operation,
repellant force suspends the shaft in the bearing. Because there is
no direct contact between the shaft and the bearing, neither noise
nor friction is generated therebetween. The magnetic bearing,
however, must be designed with a gap of about 0.2 mm between the
shaft and the bearing, such that balanced force toward the center
point is generated by each portion of the bearing surrounding the
shaft. However, if the position of the shaft is offset by external
force or driving force during operation, the imbalance can cause
shaft contact with the bearing. This increases noise, shortens
lifetime, and can even interrupt normal operation of the motor.
[0011] Furthermore, since the magnetic bearing is based on magnetic
balance, there are occasions that the motor cannot be smoothly
started. Thus, the magnetic bearing is still in an experimental
stage, as yet unable to be mass produced.
SUMMARY
[0012] Accordingly, an object of the present invention is to
provide a motor minimizing problems associated with bearings.
[0013] The present invention provides a motor comprising a stator,
a rotor, a top magnetic structure, and a bottom magnetic structure.
The stator and the rotor are disposed correspondingly in a frame.
The rotor comprises a shaft, extending axially from the rotor. The
shaft does not contact the stator or the frame. The bottom magnetic
structure is disposed in the bottom of the frame. The top magnetic
structure is disposed in the top of the frame. The magnetic
structures are disposed opposite to each other in an axial
direction. Magnetic attraction generated between the magnetic
structures positions the shaft therebetween such that the first
magnetic structure, the second magnetic structure, and the shaft
are coaxially aligned.
[0014] According to the motor of the present invention, the shaft
attracts or contacts the top magnetic structure, the bottom
magnetic structure, or the magnetic structures. Furthermore, the
motor includes at least one wear-resistant structure, disposed
between the shaft and the bottom magnetic structure, the shaft and
the top magnetic structure, or the shaft, the top, and the bottom
magnetic structures. The shaft contacts the wear-resistant
structure at a contact point.
[0015] Accordingly, the motor further includes a magnetic structure
encircling the rotor and a permeable structure encircling the
stator and disposed corresponding to the magnetic structure
encircling the rotor. The magnetic structure encircling the rotor
includes a magnetic central plane, positioned slightly higher or
lower than, or level with the magnetic central plane of the
permeable structure in an axial direction.
[0016] Furthermore, in the present invention, when the stator is
covered by the rotor, the shaft extends through the central opening
of the stator, and a protective structure is formed on a sidewall
of the opening without directly contacting the shaft.
[0017] In addition, the end surface of the shaft is selected from
the group consisting of flat, curved, pointed, concave, convex, and
combinations thereof, as is the end portion of the top or bottom
magnetic structure facing the end surface of the shaft
correspondingly. Moreover, the shape of an end of the
wear-resistant structure facing the axle shaft also corresponds to
that of the shaft point.
[0018] In the motor of the invention, a plurality of blades
surround the periphery of the rotor. The blades are centrifugal,
planar, or axial. The frame comprises an upper cover and a lower
cover, connected by fitting, engaging, gluing, locking, connecting
via a cushion device, or combinations thereof and corresponding to
each other.
[0019] Accordingly, the upper and lower magnetic structures and the
shaft are coaxial.
[0020] The present invention also provides a motor, applicable in a
fan assembly, comprising a stator, a rotor, a plurality of blades,
and at least one magnetic structure. The stator is disposed on a
base comprising at least one permeable structure. The rotor
comprises a shaft. The shaft extends axially from the rotor. The
magnetic structure encircles the rotor, corresponding to the
permeable structure. The blades surround the periphery of the
rotor, and the magnetic structure is fastened on the base via
magnetic attraction to position the shaft. The magnetic structure
contacts the shaft at a contact point. The magnetic central plane
of the rotor is positioned substantially higher than the magnetic
central plane of the stator.
[0021] As a result, the rotor shaft contacts the stator at a
contact point. During operation, buoyant force or lifting force is
generated by airflow without making direct contact, thereby greatly
reducing noise from the motor and increasing the lifetime.
[0022] Moreover, the motor of the present invention is operated via
magnetic attraction of the shaft and buoyant force is generated
during rotation by airflow, and thus, noise from the motor is
reduced and lifetime is increased. The motor with a conventional
bearing is replaced by the motor of the invention to eliminate
components and reduce assembly costs thus minimizing manufacturing
cost.
[0023] Further scope of the applicability of the present invention
will become apparent from the detailed description given
hereinafter. However, it should be understood that the detailed
description and specific examples, while indicating preferred
embodiments of the invention, are given by way of illustration
only, since various changes and modifications within the spirit and
scope of the invention will become apparent to those skilled in the
art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The present invention will become more fully understood from
the detailed description given hereinbelow and the accompanying
drawings which are given by way of illustration only, and thus are
not limitative of the present invention, and wherein:
[0025] FIG. 1 is a schematic diagram of a motor according to a
first embodiment of the present invention;
[0026] FIG. 2 is a schematic diagram of a motor according to a
second embodiment of the present invention;
[0027] FIGS. 3A to 3D are local enlarged schematic diagrams of a
shaft of the motor according to the present invention;
[0028] FIG. 4 is a schematic diagram of a motor according to a
third embodiment of the present invention;
[0029] FIG. 5 is a schematic diagram of a motor according to a
fourth embodiment of the present invention.
DETAILED DESCRIPTION
[0030] FIG. 1 is a schematic diagram of a motor according to a
first embodiment of the present invention. The motor 100 comprises
a frame 102, a stator 104, a rotor 106, and magnetic structures 108
and 110. A shaft 116 extends axially from the rotor 106. The shaft
116 and the magnetic structures 108 and 110 are aligned coaxially.
In the motor 100, the magnetic attraction is generated between the
magnetic structures 108 and 110 and the shaft 116.
[0031] The frame 102 protects the motor 100 and internal elements
thereof from external force. The frame 102 is either integrally
formed or comprises an upper and a lower cover 102a and 102b. The
frame 102 may also be formed by a plurality of divided portions
(not shown). The covers 102a and 120b are connected by fitting,
engaging, gluing, locking, or connecting via a cushion device.
Furthermore, the upper and lower covers 102a and 102b are
correspondingly engaged, for example, engaged by a hook, as shown
in FIG. 1.
[0032] The stator 104 is disposed in the frame 102 to produce
induced current or provide driving force for the rotor 106. The
stator 104 comprises a printed circuit board (not shown), a stator
fixing base 112, and at least a permeable structure 114. The stator
104 does not contact the shaft 116 described later. The permeable
structure 114 surrounds the base 112 and comprises a magnetic
central plane P1. The permeable structure 114 can be a silicon
steel plate or an electromagnet.
[0033] The rotor 106 is movably disposed in the frame 102,
corresponding to the stator 104. The rotor 106 comprises the shaft
116, rotor 132, at least one magnetic structure 118, a permeable
cover 120. The shaft 116 comprises a flat, curved, pointed,
concave, or convex end surface.
[0034] The magnetic structure 118 comprises a magnetic central
plane P2. The magnetic structure 118 corresponds to the permeable
structure 114. The magnetic central plane P1 is positioned higher,
level with, or lower than the magnetic central plane P2 in the
axial direction of the shaft. The magnetic structure 118 is a
permanent magnet or a plastic magnet.
[0035] In addition, the rotor 106 further comprises a plurality of
blades for producing airflow around the motor 100 during rotation
of the rotor 106. The type of the blades 122 can be centrifugal,
planar, or axial.
[0036] The magnetic structures 108 and 110 are disposed on the
bottom and the top of the frame 102, respectively, corresponding to
a respective end of the shaft. The magnetic structures 108 and 110
are permanent magnets, plastic magnets, or electromagnets. The two
structures 108 and 110 can be connected and fastened on the frame
102 by gluing, fitting, engaging, or contacting. The surfaces of
the magnetic structures 108 and 110 facing each other have opposite
polarities therebetween. The surface of the magnetic structures 108
and 110 facing the shaft 116 and the end surface of the shaft 116
are curved, where the magnetic structures 108 and 110 contact the
shaft 116 at a contact point. The surface shape can be flat,
curved, pointed, concave, or convex.
[0037] The magnetic structures 108 and 110 and the shaft 116 are
coaxially maintained by the magnetic attraction therebetween such
that the shaft 116 is positioned between the magnetic structures
108 and 110. When the motor 100 is idle, the shaft 116 also can
only contact the magnetic structure 108 at a contact point, without
contacting other elements.
[0038] Furthermore, the shaft 116 also may only contact the other
magnetic structure 110 at a contact point such that the rotor 106
is suspended in the frame 102.
[0039] Moreover, the shaft 116 can also contact the magnetic
structures 108 and 110 at a contact point simultaneously.
[0040] To further increase the lifetime of the motor 100,
wear-resistant structures 124 and 126 may be additionally disposed
between the shaft 116 and the magnetic structures 108 and 110. In
this case, the shaft 116 only contacts the wear-resistant
structures 124 and/or 126 at a contact point. The wear-resistant
structures 124 and 126 are fixed onto the magnetic structures 108
and 110 respectively. The wear-resistant structures 124 and 126 can
be formed on the magnetic structures 108 and 110 simultaneously or
at the intersection between the shaft 116 and the magnetic
structures. Put simply, the wear-resistant structure 124 is formed
on the magnetic structure 108, and the wear-resistant structure 126
is formed on the magnetic structure 110. The wear-resistant
structures 124 and 126 are formed thereon by gluing, engaging,
fitting, contacting, or combinations thereof. The wear-resistant
structures 124 and 126 can either directly contact or not contact
the magnetic structures 108 and/or 110 and are coaxially aligned
with the magnetic structures 108 and 110.
[0041] Furthermore, to prevent damage on the motor 100 due to
impact between the shaft 116 and the stator fixing base 112 during
transport, a protective structure 128 can be disposed on an opening
130 at an inner side of the stator fixing base 112. The protective
structure 128 does not contact the shaft 116. The material of the
protective structure 128 can be selected from the group consisting
of plastic, flexible material, vibration absorbing material, and
combinations thereof.
[0042] FIG. 2 is a schematic diagram of a motor 200 according to a
second embodiment of the present invention, from which elements
common to the first embodiment are omitted. The difference is that
only one magnetic structure 202 is used to attract the shaft 116 of
the rotor 106. The magnetic central plane P2 of the magnetic
structure 118 is higher than the magnetic central plane P1 of the
permeable structure 114 in an axial direction with respect to a
base 208.
[0043] In this embodiment, the magnetic structure 202 is entirely
made of a magnetic material, or formed by a wear-resistant
structure 206 and a magnetic body 204. Moreover, the surface
between the magnetic structure 202 and the shaft 116 or the surface
between the wear-resistant structure 206 and the shaft 116 is
curved with a contact point therebetween. The surface of the
magnetic structure 202 and/or the wear-resistant structure 206 is
curved, pointed, concave, convex, or combinations thereof. The
relationship between the shaft 116 and the magnetic structure 202
is the same as the above description.
[0044] When an end of a shaft 116a or 116b has a pointed shape, the
surface of the magnetic structure 202a or 202b is curved or shaped
in concave corresponding to the end of the shaft 116a or 116b as
shown in FIG. 3A or 3B.
[0045] Furthermore, as shown in FIG. 3C, a curved end of a shaft
116c is corresponding to a convex end of the protruding magnetic
structure 202c. Similarly, as shown in FIG. 3D, the shaft 116d has
a differently shaped depression corresponding to the pointed
magnetic structure 202d.
[0046] FIG. 4 is a schematic diagram of a motor 300 according to a
third embodiment of the present invention, from which elements
common to said embodiments are omitted. The difference is that a
magnetic structure 304 is disposed on the top of the stator fixing
base 112, and a magnetic structure 302 is formed on the rotor hub
132. The magnetic structures 302 and 304 are attracted to each
other without making contact. The magnetic structure 304 does not
contact the permeable structure 114 and is positioned higher than
the permeable structure 114 in an axial direction. The magnetic
structure 302 is a circular, fan-shaped, block-shaped, or
rectangular structure. The shape and position of the magnetic
structure 302 correspond to those of the magnetic structure
304.
[0047] Furthermore, the magnetic structure 304 and the stator
fixing base 112 are connected by gluing, fitting, engaging,
contacting, or combinations thereof. The magnetic structure 302 and
the rotor hub 132 are also connected by gluing, fitting, engaging,
contacting, or combinations thereof.
[0048] FIG. 5 is a schematic diagram of a motor 400 according to a
fourth embodiment of the present invention, from which elements
common to said embodiments are omitted. The difference is that
there is only one magnetic structure 402 formed on an upper cover
102a of the frame 102. The magnetic central plane P2 of the
magnetic structure 118 is lower than the magnetic central plane PI
of the permeable structure 114 in an axial direction. Moreover, a
wear-resistant structure 408 is disposed at a lower cover 102b.
[0049] In this embodiment, the magnetic structure 402 is entirely
made of a magnetic material, or formed by a wear-resistant
structure 406 and a magnetic body 404. Moreover, the surface
between the magnetic structure 402 and the shaft 116, the surface
between the wear-resistant structure 406 and the shaft 116, and/or
the surface between the wear-resistant structure 408 and the shaft
116 is a curved surface with a contact point therebetween. The
surface shape of the magnetic structure 402 and/or the
wear-resistant structures 406, 408 is curved, pointed, concave,
convex, or combinations thereof.
[0050] The motor described above is applied in an axial flow fan.
The present invention, however, is not limited to the disclosed
fan. The motor is also applicable in other fans such as frameless,
centrifugal, outer-rotor, or inner-rotor fan.
[0051] In the above embodiments, the shaft of the rotor has only
one point of contact with the stator or no contact therebetween
when buoyant airflow force is generated during rotation. Thus, the
noise level of the motor is greatly reduced and lifetime is
increased.
[0052] Furthermore, the motor of the present invention generates
buoyant force by magnetic attraction from the shaft during
operation such that the shaft does not contact other elements thus
reducing noise and increasing the lifetime of the motor.
[0053] The motor of the present invention does not require the
conventional bearing, thus reducing the number of elements in the
motor, thereby minimizing the manufacturing cost.
[0054] While the invention has been described by way of example and
in terms of the preferred embodiments, it is to be understood that
the invention is not limited to the disclosed embodiments. To the
contrary, it is intended to cover various modifications and similar
arrangements (as would be apparent to those skilled in the art).
Therefore, the scope of the appended claims should be accorded the
broadest interpretation so as to encompass all such modifications
and similar arrangements.
* * * * *