JP2018014869A - Fan motor and fan motor manufacturing method - Google Patents

Abstract

An object of the present invention is to provide a fan motor and a method of manufacturing the fan motor, which can prevent water from entering from between a lead wire drawn out of the motor and a filler covering a circuit board. A motor for rotating an impeller, a circuit board on which a plurality of electronic components are mounted, a first casing for accommodating the impeller and the motor, and a circuit board disposed outside the first casing. It has a second casing 6 to be housed therein and a lead wire 7 extending from the motor. The first casing has a top plate 51 provided with an intake port 52 penetrating in the axial direction, and a base portion 53 located below the top plate and supporting the motor. The second casing has a through hole 62 provided on the lower surface and penetrating in the axial direction, and a connector 8 having connection pins 81 for electrically connecting a lead wire and a circuit board. The lower surface of the circuit board covers the upper part of the through hole, the upper surface of the connector covers the lower part of the through hole, and at least a part of the circuit board is covered with the filler 61. [Selection diagram] Fig. 1

Description

  The present invention relates to a fan motor and a method for manufacturing the fan motor.

  Conventionally, a fan motor in which a circuit board is disposed outside the fan motor is known. For example, Patent Document 1 discloses a technique related to an impeller motor in which a part of a circuit board is disposed outside a casing.

  When such a fan motor is used for an application exposed to an external environment, a circuit board on which electronic components are mounted is sealed with a filler. The space where the circuit board is sealed with the filler is different from the space where the motor is arranged.

JP 2008-215330 A

  The space in which the circuit board is sealed with the filler is different from the space in which the motor is disposed and is separated from the wall. The circuit board is electrically connected to the motor of the fan motor via a lead wire. The lead wire is connected to the circuit board across the wall from the side on which the motor is disposed, which is the side opposite to the side on which the filler is disposed. In this case, one side of the lead wire is arranged inside the filler, and the other side is arranged outside the filler. Thereby, when a lead wire bends, a clearance gap will arise between a lead wire and a filler, and there exists a possibility that water may penetrate | invade from a clearance gap.

  An object of the present invention is to provide a fan motor and a fan motor manufacturing method capable of suppressing water from entering between a lead wire drawn from the motor and a filler covering a circuit board.

  A fan motor according to an exemplary embodiment of the present invention includes an impeller having a plurality of blades around a central axis extending vertically, a motor for rotating the impeller around the central axis, and a plurality of electronic components. A circuit board, a first casing that houses the impeller and the motor, a second casing that is disposed outside the first casing and houses the circuit board, and a lead wire extending from the motor. The first casing includes a top plate provided with an intake port penetrating in the axial direction, and a base portion that is located below the top plate and supports the motor, and the second casing is A through hole provided in the lower surface of the second casing and extending in the axial direction; and a connector having a connection pin for electrically connecting the lead wire and the circuit board, The lower surface covers the upper portion of the through-hole, the upper surface of the connector covers the lower portion of the through hole, at least a portion of the circuit board is covered with a filler.

  A fan motor manufacturing method according to an exemplary embodiment of the present invention includes an impeller having a plurality of blades around a central axis extending vertically, a motor for rotating the impeller around the central axis, and a plurality of electronic components. A circuit board on which components are mounted, a top plate that houses the impeller and the motor and has an air inlet that passes through in the axial direction, and a base portion that is located below the top plate and supports the motor And a lead casing extending outside the first casing and having a through-hole penetrating in the axial direction on the lower surface, and a lead wire extending from the motor. In step S1, the upper surface of the through hole is covered with the lower surface of the circuit board, the step S2 of covering the lower portion of the through hole with the upper surface of the connector having the connection pin, and the second casing. Step S3 of pouring a filler into a portion where the circuit board is disposed and curing the filler; and drawing out the lead wire from the base portion and connecting it to the connection pin; and connecting the circuit board and the lead wire Electrically connecting step S4.

  According to the fan motor and the fan motor manufacturing method of an exemplary embodiment of the present invention, the lead wire drawn from the motor of the first casing is electrically connected to the circuit board from the outside of the second casing having the filler. Connected to. For this reason, it can suppress that water penetrate | invades from between a lead wire and a filler.

FIG. 1 is a longitudinal sectional view of a fan motor according to an exemplary embodiment of the present invention. FIG. 2 is a partially enlarged view of a fan motor according to an exemplary embodiment of the present invention. FIG. 3 is a perspective view of a fan motor according to an exemplary embodiment of the present invention. FIG. 4 is a perspective view of a fan motor according to an exemplary embodiment of the present invention. FIG. 5 is a partial enlarged cross-sectional view of a fan motor according to an exemplary embodiment of the present invention. FIG. 6 is a flowchart illustrating an example of a procedure for assembling a fan motor according to an exemplary embodiment of the present invention.

  Hereinafter, exemplary embodiments of the present invention will be described with reference to the drawings. In the present application, the direction parallel to the central axis 9 of the fan motor 1 is “axial direction”, the direction orthogonal to the central axis 9 of the fan motor 1 is “radial direction”, and the central axis 9 of the fan motor 1 is the center. The direction along the arc is referred to as “circumferential direction”.

  FIG. 1 is a longitudinal sectional view of a fan motor 1 according to a first embodiment of the present invention, cut along a plane including a central axis. The fan motor 1 is a fan motor 1 that is mounted on equipment such as a server, a router, a communication base, a switch device, etc., and generates a cooling airflow. However, the fan motor 1 of the present invention may be mounted on a transport device such as an automobile, a home appliance, an OA device, or a medical device.

  As shown in FIG. 1, the fan motor 1 includes an impeller 2, a motor 3, a circuit board 4, a first casing 5, a second casing 6, and a lead wire 7. The motor 3 rotates the impeller 2 around the central shaft 9. A plurality of electronic components 41 are mounted on the circuit board 4 to control the rotation of the motor 3. The first casing 5 accommodates the impeller 2 and the motor 3. The second casing 6 is disposed outside the first casing 5 and accommodates the circuit board 4. The lead wire 7 extends from the motor 3 and is electrically connected to the circuit board 4.

  The impeller 2 is a resin member that rotates together with a shaft 321 described later. The impeller 2 includes a blade support portion 21, a plurality of blade portions 22, and a convex portion 23. The blade support portion 21 is in contact with the axially upper end portion of the rotor holder 323 described later. The plurality of blade portions 22 are arranged in the circumferential direction on the radially outer side of the blade support portion 21 and the rotor holder 323. The convex portion 23 projects downward from the center of the blade support portion 21.

  The motor 3 includes a stator 31, a rotor 32, a bearing 33, and a motor circuit board 34. The rotor 32 is supported by a bearing 33 so as to be rotatable with respect to the stator 31 about the central axis 9.

  The stator 31 includes a stator core 311, a coil 312, and an insulator 313. The stator core 311 is made of a laminated steel plate in which electromagnetic steel plates such as silicon steel plates are laminated in the axial direction. The coil 312 is constituted by a conductive wire wound around the insulator 313. That is, in the present embodiment, a conductive wire is wound around the stator core 311 via the insulator 313. The insulator 313 is disposed between the stator core 311 and the coil 312 to electrically insulate the stator core 311 and the coil 312 from each other.

  The rotor 32 includes a shaft 321, a rotor holder 323, and a magnet 324.

  The shaft 321 is a columnar member extending in the axial direction. The shaft 321 is made of a metal such as stainless steel, for example. The shaft 321 is inserted inside the bearing 33. Accordingly, the shaft 321 is rotatably supported with respect to the bearing 33. The shaft 321 has a head 322 that protrudes upward from the upper surface of the bearing 33. The head portion 322 is fixed to the convex portion 23 of the blade support portion 21 by insert molding or the like.

  The rotor holder 323 is a metal member fixed to the impeller 2. The rotor holder 323 is obtained, for example, by pressing a metal plate material.

  The magnet 324 is located on the radially outer side of the stator core 311. The magnet 324 is fixed to the inner peripheral surface of the rotor holder 323 with an adhesive, for example. The magnet 324 of the present embodiment has an annular shape.

  The bearing 33 supports the shaft 321 on the radially inner side of the stator 31. The bearing 33 is accommodated inside the radial direction of the inner cylinder part 532 mentioned later. In the present embodiment, the bearing 33 is a cylindrical sintered bearing. However, a fluid bearing or a ball bearing may be used instead of the sintered bearing.

  The motor circuit board 34 is a board for electrically connecting the circuit board 4 on which the electronic component 41 is mounted and the motor 3. The motor circuit board 34 is disposed below the coil 312 and the magnet 324. The motor circuit board 34 is fixed by, for example, engaging the edge of a circular hole provided in the center with a claw part provided in the insulator 313. The ends of the conductive wires constituting the coil 312 are soldered to the upper surface of the motor circuit board 34. Note that the conductive wire constituting the coil 312 may be connected to the upper surface of the motor circuit board 34 via a conduction pin.

  A lead wire 7 for inputting / outputting electric signals is connected to the motor circuit board 34. The lead wire 7 is fixed to a fixing portion 35 provided on the lower surface of the motor circuit board 34. The fixing part 35 is made of, for example, solder. The lead wire 7 extends from the motor 3. That is, the lead wire 7 extends radially outward from the fixing portion 35 to the second casing 6.

  The circuit board 4 is electrically connected to the motor circuit board 34 via the lead wire 7 and the connection pin 81. A plurality of electronic components 41 are mounted on the circuit board 4. The drive current supplied to the stator 31 via the electronic component 41 mounted on the circuit board 4 is controlled. As a result, torque about the central axis 9 is generated between the stator 31 and the magnet 324. As a result, the shaft 321 and the impeller 2 attached to the shaft 321 rotate about the central axis 9.

  FIG. 2 is a partially enlarged view of the fan motor 1 according to an exemplary embodiment of the present invention. FIG. 3 is a perspective view of the fan motor 1 according to the first embodiment of the present invention as viewed from above. The first casing 5 includes a top plate 51, a base portion 53, and a side wall 54. The top plate 51 includes an intake port 52 that penetrates in the axial direction. The base portion 53 is located below the top plate 51 and supports the motor 3. The side wall 54 is disposed between the top plate 51 and the base portion 53 and extends along the axial direction. The base part 53 includes a bottom plate part 531 and an inner cylinder part 532. The bottom plate portion 531 extends substantially perpendicular to the central axis 9 on the lower side in the axial direction of the motor 3. The inner cylinder portion 532 extends in a substantially cylindrical shape from the upper surface of the bottom plate portion 531 upward around the central axis 9.

  The second casing 6 includes a filler 61, a through hole 62, and a connector 8. At least a part of the circuit board 4 is covered with the filler 61. The filler 61 is made of, for example, silicon or urethane. In the present embodiment, the entire circuit board 4 is covered with the filler 61. That is, the upper surface and the periphery of the circuit board 4 are covered with the filler 61. For this reason, the waterproofness with respect to the electronic component 41 mounted in the circuit board 4 can be improved. More preferably, the filler 61 covers the electronic component 41 mounted on the circuit board 4. For this reason, waterproofness can be improved further.

  The through hole 62 is provided on the lower surface of the second casing 6 and penetrates in the axial direction. The circuit board 4 is disposed in the second casing 6 so as to close the through hole 62. That is, the lower surface of the circuit board 4 covers the upper part of the through hole 62. Further, the connector 8 is disposed in the second casing 6 so as to close the through hole 62. That is, the upper surface of the connector 8 covers the lower part of the through hole 62. By covering the opening of the through hole 62 with the circuit board 4 and the connector 8 in the vertical direction of the through hole 62, it is possible to prevent water from entering the electronic component 41 mounted on the circuit board 4.

  In the present embodiment, the case where the circuit board 4 and the connector 8 cover the through hole 62 has been described, but this is not restrictive. For example, the circuit board 4 or the connector 8 need not completely cover the through hole 62. That is, a part of the opening of the through hole 62 may have a gap between the circuit board 4 and the edge of the connector 8. In this case, the gap may be sealed with the filler 61. Further, a resin such as an adhesive may be sealed between the lower surface of the circuit board 4 or the upper surface of the connector 8 and the second casing 6 that is the edge of the through hole 62. The resin may be the filler 61 or another material. By sealing a resin such as an adhesive between the lower surface of the circuit board 4 or the upper surface of the connector 8 and the second casing 6 that is the edge of the through hole 62, the waterproof property can be further improved.

  As shown in FIG. 2, the through hole 62 is disposed in the second groove 63. At least a part of the circuit board 4 is arranged with a gap 64 in the axial direction from the lower surface of the second casing 6. At least a part of the electronic component 41 is disposed in the gap 64. For this reason, the electronic component 41 can also be mounted on the lower surface of the circuit board 4. The electronic components 41 can be mounted on the upper surface and the lower surface of the circuit board 4, respectively. By arranging electronic components on a small board plane, the circuit board 4 can be reduced in size.

  FIG. 4 is a perspective view of the fan motor 1 according to the first embodiment of the present invention as viewed from below. The first casing 5 has a first groove 55 that extends from the motor 3 to the second casing 6 and is recessed on the upper side in the axial direction on the lower surface of the base portion 53. The second casing 6 has a second groove 63 that is recessed on the upper side in the axial direction on the lower surface and accommodates at least a part of the connector 8. The lead wire 7 is disposed in the first groove 55 and the second groove 63. The lead wire 7 is easily pulled out along the first groove 55 or the second groove 63.

  The lead wire 7 is drawn from the motor 3 toward the second casing 6 on the base portion 53, and is connected to the connection pin 81 on the lower side of the lower surface of the second casing 6. That is, the lead wire 7 is electrically connected to the circuit board 4 via the connection pin 81. Thereby, the lead wire 7 drawn out from the motor 3 is electrically connected to the circuit board 4 from the outside of the second casing 6 having the filler 61. That is, the lead wire 7 is disposed in a portion different from the circuit board 4 covered with the filler 61 in the second casing 6 and is electrically connected to the circuit board 4.

  When a part of the lead wire 7 is covered with the same filler 61 as the filler 61 covering the circuit board 4, there is a possibility that water may enter from the gap between the lead wire 7 and the filler 61. For example, the lead wire 7 extends from the motor circuit board 34 toward the upper side in the axial direction, and is connected to the circuit board 4 from the upper side in the axial direction of the first casing 5 through the inside of the second casing 6 and the inside of the filler 61. In this case, the end of the lead wire 7 on the first casing 5 side is not covered with the filler 61, and the end of the lead wire 7 on the second casing 6 side is covered with the filler 61. In this case, when a gap is generated between the lead wire 7 and the filler 61 at the end of the lead wire 7 on the second casing 6 side, there is a possibility that water may enter from the gap. In the present embodiment, the lead wire 7 is arranged in a portion different from the circuit board 4 covered with the filler 61. Thereby, it can suppress that a clearance gap produces between the lead wire 7 and the filler 61, and can improve waterproofness.

  The lead wire 7 may be covered with a filler different from the filler 61 in a portion different from the second casing 6 in which the circuit board 4 is disposed. Although illustration is omitted, for example, the lead wire 7 may be covered with the filler in the first groove 55, and the connector 8 and the lead wire 7 may be covered with the filler in the second groove 63. That is, the lead wire 7 may be disposed inside the filler 61 in the first groove 55 and the second groove 63. Thereby, it can suppress that a clearance gap produces between a lead wire and the filler 61. FIG. Water can be prevented from entering the lead wire 7 along the first groove 55 and the second groove 63, and the waterproofness is further improved. The filler covering the lead wire 7 in the first groove 55 and the second groove 63 may be the same material as the filler 61 covering the circuit board 4 in the second casing 6, or another It may be a material.

  FIG. 5 is a partially enlarged cross-sectional view of the fan motor 1 according to the first embodiment of the present invention. The upper surface of the connector 8 covers the lower part of the through hole 62. The connector 8 has connection pins 81 that electrically connect the lead wire 7 and the circuit board 4. The connector 8 has a plurality of connection pins 81. In the present embodiment, three connection pins 81 are provided. The upper portion of the connection pin 81 is disposed on the upper surface of the circuit board 4 through a hole provided in the circuit board 4. The upper part of the connection pin 81 is fixed to the upper surface of the circuit board 4 by soldering, for example. The connection pin 81 passes through the through hole 62. A lower portion of the connection pin 81 is disposed on the lower surface of the connector 8 through a hole provided in the connector 8. That is, the connector 8 has a plurality of connection pins 81 on the side where the lead wire 7 is disposed. The connection pin 81 has a pair of branch pins 82 whose lower end branches into two. The lead wire 7 is sandwiched between a pair of branch pins 82. Thereby, the lead wire 7 and the connection pin 81 can be easily connected.

  In the pair of branch pins 82, one branch pin 82 has a protruding portion 83 that protrudes toward the other branch pin 82. A substantially annular lead wire accommodating space 84 is formed by the pair of protrusions 83. The lead wire 7 is sandwiched between lead wire accommodation spaces 84 formed by the protrusions 83. Thereby, it can suppress that the lead wire 7 moves to an axial direction.

  In the present embodiment, the fan motor 1 is an axial fan, but is not limited thereto. For example, the fan motor 1 may be a centrifugal fan in which an exhaust port is provided on a side surface. That is, the first casing 5 has a side wall 54 having an exhaust port between the top plate 51 and the base portion 53. The second casing 6 is disposed on the opposite side to the exhaust port with respect to the virtual plane along the vertical direction. For this reason, the target object to cool can be arrange | positioned to the exhaust-port side, and it can cool efficiently.

  Subsequently, a part of the manufacturing procedure of the fan motor 1 will be described. FIG. 6 is a flowchart showing an example of an assembly procedure of the circuit board 4 and the lead wire 7 in the manufacturing process of the fan motor 1.

  In the example of FIG. 6, first, the upper surface of the through hole 62 is covered with the lower surface of the circuit board 4 (step S1). Next, the lower surface of the through hole 62 is covered with the upper surface of the connector 8 having the connection pins 81 (step S2). Thereby, the through hole 62 is covered with the circuit board 4 and the connector 8. Subsequently, the filler 61 is poured into the portion of the second casing 6 where the circuit board 4 is disposed, and the filler 61 is cured (step S3). Thereby, the 2nd casing 6 is obtained.

  Thereafter, the lead wire 7 is pulled out from the motor 3 and connected to the connection pin 81 to electrically connect the circuit board 4 and the lead wire 7 (step S4). In the present embodiment, in step S4, a connector 8 is prepared, on the side where the lead wire 7 is disposed, and the connection pin 81 has a pair of branch pins 81 whose front ends branch into two. Thereafter, the lead wire 7 is pressed between the pair of branch pins 81. Thereby, the lead wire 7 can be electrically connected easily.

  The second casing 6 may be a separate member from the first casing 5. In that case, the manufacturing method of the fan motor 1 includes a step S6 provided after the step S4 and disposing the second casing 6 outside the first casing 5. Thereby, the 2nd casing 6 and the 1st casing 5 are created, respectively. That is, when the filler 61 is cured, only the second casing 6 is disposed in the thermostatic bath. For this reason, the space required for the thermostat can be made smaller than when the filler 61 is cured after the first casing 5 and the second casing 6 are connected.

  In the present embodiment, in step S4, on the lower surface of the base portion 53, on the lower surface of the first casing 5 having the first groove 55 extending from the motor 3 to the second casing 6 and recessed toward the inlet 52 side, A second casing 6 having a second groove 63 that is recessed toward the inlet 52 side and that accommodates at least a part of the connector 8 is prepared. Thereafter, the lead wire 7 is pulled out from the motor 3 and connected to the connection pin 81 through the first groove 55 and the second groove 63. Thereby, the lead wire 7 is easily pulled out along the first groove 55 or the second groove 63.

  The first casing 5 and the second casing 6 may be thickened in order to increase the strength. However, when the 1st casing 5 and the 2nd casing 6 are shape | molded with a resin material, a thick part may sink by solidification of a resin material. By providing the first groove 55 and the second groove 63, the depression can be suppressed.

  The present invention can be used for a fan motor and a method for manufacturing the fan motor.

Reference Signs List 1 fan motor 2 impeller 21 blade support portion 22 blade portion 23 convex portion 3 motor 31 stator 311 stator core 312 coil 313 insulator 32 rotor 321 shaft 322 head 323 rotor holder 324 magnet 33 bearing 34 motor circuit board 35 fixing part 4 circuit board 41 electron Component 5 First casing 51 Top plate 52 Air inlet 53 Base portion 531 Bottom plate portion 532 Inner cylinder portion 54 Side wall 55 First groove 6 Second casing 61 Filler 62 Through hole 63 Second groove 64 Gap 7 Lead wire 8 Connector 81 Connection Pin 82 Branch pin 83 Projection 84 Lead wire accommodating space 9 Central axis

Claims (11)

An impeller having a plurality of wings around a central axis extending vertically;
A motor that rotates the impeller about the central axis;
A circuit board on which a plurality of electronic components are mounted;
A first casing that houses the impeller and the motor;
A second casing disposed outside the first casing and containing the circuit board;
A lead wire extending from the motor;
With
The first casing is
A top plate with an intake port penetrating in the axial direction;
A base portion located below the top plate and supporting the motor;
Have
The second casing is
A through hole provided in the lower surface of the second casing and penetrating in the axial direction;
A connector having a connection pin for electrically connecting the lead wire and the circuit board;
Have
The lower surface of the circuit board covers the upper part of the through hole,
The upper surface of the connector covers the lower part of the through hole,
A fan motor, wherein at least a part of the circuit board is covered with a filler. The fan motor according to claim 1,
The connection pin has a pair of branch pins, the lower tip of which branches into two,
The fan motor, wherein the lead wire is sandwiched between a pair of the branch pins. The fan motor according to claim 2,
In the pair of branch pins, one of the branch pins has a protruding portion that protrudes toward the other branch pin,
The fan motor, wherein the lead wire is disposed in a lead wire accommodating space formed by the protruding portion. A fan motor according to any one of claims 1 to 3,
The first casing has a first groove that extends from the motor to the second casing and is recessed on the upper side in the axial direction on the lower surface of the base portion.
The second casing has a second groove that is recessed on the upper side in the axial direction on the lower surface and accommodates at least a part of the connector,
The fan motor, wherein the lead wire is disposed in the first groove and the second groove. The fan motor according to claim 4,
In the first groove, the lead wire is covered with the filler,
The fan motor, wherein the connector and the lead wire are covered with the filler in the second groove. A fan motor according to any one of claims 1 to 5,
In the second casing, an upper surface and a peripheral edge of the circuit board are covered with the filler. The fan motor according to any one of claims 1 to 6,
At least a part of the circuit board is disposed with a gap in the axial direction with the lower surface of the second casing,
A fan motor in which at least a part of the electronic component is disposed in the gap. An impeller provided with a plurality of blades around a central axis extending vertically, a motor for rotating the impeller around the central axis, a circuit board on which a plurality of electronic components are mounted, the impeller and the motor are accommodated A first casing having a top plate provided with an intake port penetrating in the axial direction, a base portion that is positioned below the top plate and supports the motor, and is disposed outside the first casing. In a method for manufacturing a fan motor, comprising: a second casing having a through-hole penetrating in the axial direction on the lower surface; and a lead wire extending from the motor.
A step S1 of covering the upper portion of the through hole with the lower surface of the circuit board;
A step S2 of covering the lower portion of the through hole on the upper surface of the connector having the connection pins;
Pouring a filler into a portion of the second casing where the circuit board is disposed, and curing the filler; S3;
Step S4 of pulling out the lead wire from the motor, connecting to the connection pin, and electrically connecting the circuit board and the lead wire;
Manufacturing method. In the manufacturing method of the fan motor according to claim 8,
A manufacturing method including a step S5 provided after the step S3 and disposing the second casing outside the first casing. In the manufacturing method in any one of Claim 8 or 9,
The step S4 includes
Manufacturing the connector on the side where the lead wire is arranged and having a connection pin that is a pair of branch pins with the tip branching into two, and press-contacting the lead wire between the pair of branch pins Method. In the manufacturing method in any one of Claim 8 to 10,
The step S4 includes
The first casing having a first groove extending from the motor to the second casing and recessed toward the intake port on the lower surface of the base portion, and recessed toward the intake port on the lower surface, Preparing the second casing having a second groove for accommodating at least a part of the connector;
A manufacturing method in which the lead wire is pulled out from the motor and connected to the connection pin through the first groove and the second groove.

Images