Electrical generator or motor structure – Dynamoelectric – Rotary
Reexamination Certificate
1999-07-23
2001-05-15
Tamai, Karl (Department: 2834)
Electrical generator or motor structure
Dynamoelectric
Rotary
C310S156030, C310S063000, C417S423200, C417S423700
Reexamination Certificate
active
06232696
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a vacuum generating apparatus for a vacuum cleaner, and more particularly, to a vacuum generating apparatus for a vacuum cleaner in which an axial type coreless brushless direct-current (DC) motor is implemented in the form of a rotor-impeller integration structure, to thereby realize ultra-compactness, thinness, light-weight, low-noise, long lifetime, non-existence of carbon dust, and improved productivity.
2. Description of the Related Art
In accordance with development of electronics industry, a vacuum cleaner has become more compact, thinner and lighter. However, such reduction in size has confronted to a saturated state due to limitation of lengthy direction of a motor being an essential component in a vacuum cleaner.
In general, as the type of a vacuum cleaner, there are a traditional type as shown in
FIG. 1
, and an upright type and a canister type both of which are adopted in Europe. In all types of vacuum cleaners, compactness and lightness of the whole volume and weight are regarded as matters to be solved together with easiness of cleaning. In particular, in the case of an upright type of a vacuum cleaner, a big load is applied to hands during cleaning, to thereby cause much fatigue and inconvenience a user due to a large volume.
The structure of a conventional vacuum cleaner will be described below with reference to
FIGS. 1 and 2
.
In the conventional vacuum cleaner of
FIG. 1
, a motor
3
is incorporated in the inside of a housing
1
of a main body in which an impeller is fixed to a rotating shaft in order to generate a vacuum sucking force. Here, wheels
2
are rotatably installed on the lower portion of the main body. A dust bag
4
for accommodating dust is installed at the front stage of the motor
3
. A dust sucking device
6
is detachably and attachably connected via a vacuum flexible hose tube
5
at the next end of the dust bag
4
. A filter
7
is provided at the rear end of the housing
1
.
In the conventional vacuum cleaner, the impeller is rotated due to driving of the motor
3
, to thereby generate a sucking force. Accordingly, dust is absorbed into the dust bag
4
via the sucking device
6
.
In a vacuum generating apparatus for a vacuum cleaner using a conventional alternating-current (AC) universal motor, as shown in a partially exploded sectional view of
FIG. 2
, both ends of a rotating shaft
8
of a rotor whose rotor coil
9
is wound around a core
9
a
are rotatably supported by bearings
10
and
20
fixed to a housing
16
of the motor
3
. An electromagnet
11
for a stator is arranged with a predetermined gap along the external circumferential portion of th coil
9
.
An impeller
12
is combined at the upper end of the rotating shaft
8
via an upper bearing
10
and a pair of washers
13
and fixed by a nut
14
and a fixing bolt
15
.
Here, an electric power source for driving a motor is applied from a carbon brush
19
which is elastically supported on the housing
16
to the rotor coil
9
via a commutator
18
which is integrally formed on the lower side of the rotating shaft
8
. Accordingly, a rotating magnetic field is generated to enable the rotor to rotate.
When the impeller
12
rotates, air is sucked via an upper-center hole
17
of the housing
16
and discharged via an outlet
16
a
which is located in the lower side of the housing
16
along the air stream in the direction of an arrow, to accordingly generate a vacuum sucking force in the inside of the housing
1
of the main body.
The conventional motor used for generating a vacuum sucking force increases air sucking noise generated during high-speed rotation according to an increase of an air output. The AC universal motor having the core type brush is limited in reduction of the axial length of the motor to accomplish compactness, thinness and light weight in view of the structure of the motor. Also, an air guide mechanism from sucking to discharging is formed by the impeller along the axial direction of the motor, which is not so simple that an output efficiency is lowered.
In case of the conventional structure, the impeller
12
and the rotor
9
are not integrated but separate, which require particular spacers, washers, nuts and bolts, etc., to combine them. Also, an air guide vane
21
is essentially required for guiding air from the impeller
12
to the discharging outlet
16
a
in order to increase an air pressure efficiently, which causes a complicated assembly to thus lower a productivity and increase a cost.
In the case of fabrication of the conventional impeller, a number of blades and upper and lower plates which are made of aluminium plate-type materials are combined up and down in order to maintain a mechanical strength and save a weight when the impeller rotates at high speed. Thus, an offset of a vacuum degree occurs according to a tightening degree between the combined upper and lower plates and the blades. As a result, during a press assembly, a tightening combination between the upper and lower plates and the blades is in pursuit of continuous improvement.
Furthermore, in the case of the structure adopting a carbon brush, carbon dust is scattered due to wear of the brush to thereby cause an environmental pollution. The worn-out brush should be replaced by a new one, to accordingly shorten a lifetime of the motor. Also, sparks are generated between the commutator and the brush and electromagnetic waves are radiated from the motor.
To solve the above problems in part, a twin impeller, an AC inverter motor, or a brushless type motor has been adopted, but those methods are not effective nor furthermore in progress due to limitation of the axial length (105.4 mm) in size of the motor and the weight (1.35 kg) thereof.
SUMMARY OF THE INVENTION
To solve the above problems, it is an object of the present invention to provide a vacuum generating apparatus for a vacuum cleaner in which an impeller and a rotor of an axial type coreless brushless direct-current (DC) motor is implemented in the form of an integration structure, to thereby realize ultra-compactness, thinness, light-weight, low-noise, long lifetime, non-existence of carbon dust, and improved productivity.
It is another object of the present invention to provide a vacuum generating apparatus for a vacuum cleaner having a rotor-impeller integration structure in which blades and a lower plate of an impeller are integrally molded as a rotor support body by means of an insert molding method together with a divided type magnet, a magnet holder and a magnet plate of a rotor, and an upper plate of the impeller is integrally combined with the blades of rotor support body by means of an ultrasonic fusion method, to thereby an improvement of productivity and tightening adhesiveness between the upper and lower plates and the blades.
It is the other object of the present invention to provide a vacuum generating apparatus for a vacuum cleaner in which an air guide vane is not essentially required for guiding air sucked by an impeller in the housing to an air discharging outlet, and an air guiding structure is simple and subject to receive an air resistance less.
To accomplish the above object of the present invention, there is provided a vacuum generating apparatus comprising: a stator located at the center, including a number of stator coils in a disc-shaped supporter integrally; a rotating shaft which is rotatably supported in the stator; upper and lower rotors spaced by a predetermined distance from the stator and disposed at the upper and lower sides of the stator, respectively, in which a plurality of N-pole and S-pole divided magnets are alternately arranged along the circumferential direction of the upper and lower rotors each forming a disc shape, such that the upper and lower rotors are rotated by means of an interaction with an electromagnetic force of the stator coils; upper and lower impellers fixed to the upper and lower rotors, respectively; and upper and lower housings whose outer circumferential portions are
Kim Byung Kyu
Kim Joon
Amotron Co., Ltd.
Rosenberg , Klein & Lee
Tamai Karl
LandOfFree
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