Rotor for an axial flux motor
The present disclosure relates to a rotor 10 for an axial flux motor 1 . The rotor 10 comprises a rotor wheel 100 , a plurality of permanent magnets 50 and a holding structure 60 . The rotor wheel 100 comprises disk-shaped main body 110 and a plurality of arms 120 . The disk-shaped main body 110 defines an inner circumference 111 and an outer circumference 114 . The plurality of arms 120 protrude from the outer circumference 114 radially outwards to a respective arm tip 123 . The plurality of arms 120 is circumferentially distributed on the outer circumference 114 . The plurality of permanent magnets 50 is distributed circumferentially about the outer circumference 114 and arranged circumferentially between the plurality of arms 120 . The holding structure 60 is attached to the rotor wheel 100 and to the plurality of permanent magnets 50 to hold the plurality of permanent magnets 50 in position.
1. A rotor ( 10 ) for an axial flux motor ( 1 ) comprising:
a rotor wheel ( 100 ) comprising:
a disk-shaped main body ( 110 ) defining an inner circumference ( 111 ) and an outer circumference ( 114 ), and
a plurality of arms ( 120 ) protruding from the outer circumference ( 114 ) radially outwards to a respective arm tip ( 123 ), wherein the plurality of arms ( 120 ) is circumferentially distributed on the outer circumference ( 114 ),
a plurality of permanent magnets ( 50 ) distributed circumferentially about the outer circumference ( 114 ) and arranged circumferentially between the plurality of arms ( 120 ), and
a holding structure ( 60 ) being attached to the rotor wheel ( 100 ) and to the plurality of permanent magnets ( 50 ) to hold the plurality of permanent magnets ( 50 ) in position, wherein at least one of the plurality of permanent magnets ( 50 ) extends along a radial length ( 52 ) from a radial inner end ( 51 ) to a radial outer end ( 53 ), and wherein at least one of the plurality of arms ( 120 ) protrudes radially outwards to a radial position between the radial inner end ( 51 ) and the radial outer end ( 53 ) of a respective permanent magnet ( 50 ), and wherein at least one of the plurality of arms ( 120 ) extends from the outer circumference ( 114 ) radially outwards along a protruding arm length ( 122 a ) to the arm tip ( 123 ), wherein the arm tip ( 123 ) is arranged at a radial position between 0.1 to 0.9 of the radial length ( 52 ) of a permanent magnet ( 50 ).
2. The rotor ( 10 ) of claim 1 , wherein the arm tip ( 123 ) is tapered.
3. The rotor ( 10 ) of claim 1 , wherein the disk-shaped main body ( 110 ) and the plurality of arms ( 120 ) are formed integrally in one-piece.
4. The rotor ( 10 ) of claim 3 , wherein the rotor wheel ( 100 ) comprises or is made of a ceramic material or a metallic material.
5. The rotor ( 10 ) of claim 3 , wherein the rotor wheel ( 100 ) comprises or is made of an aluminum material.
6. The rotor ( 10 ) of claim 1 , wherein the holding structure ( 60 ) comprises or is made of an electrically non-conductive material, wherein the electrically non-conductive material is of a polymer.
7. The rotor ( 10 ) of claim 6 , wherein the holding structure ( 60 ) is formed by injection molding of a thermoplastic material or by injection molding of a thermosetting material.
8. The rotor ( 10 ) of claim 1 , wherein the holding structure ( 60 ) is arranged to thermally and/or electrically isolate the plurality of permanent magnets ( 50 ) from the rotor wheel ( 100 ).
9. The rotor ( 10 ) of claim 1 , wherein the holding structure ( 60 ) is attached to the plurality of arms ( 120 ) and forms a plurality of arm extensions ( 66 ) which extend radially outward from the respective arm tips ( 123 ).
10. The rotor ( 10 ) of claim 1 , wherein the holding structure ( 60 ) at least partially encapsulates a circumferentially outer region ( 113 a ) of the disk-shaped main body ( 110 ) and the plurality of arms ( 120 ).
11. The rotor ( 10 ) of claim 1 , wherein the holding structure ( 60 ) is arranged between the plurality of permanent magnets ( 50 ) and the rotor wheel ( 100 ) such that the plurality of permanent magnets ( 50 ) is not in direct contact with the rotor wheel ( 100 ).
12. The rotor ( 10 ) of claim 1 , wherein the rotor wheel ( 100 ) comprises three or more fixation structures ( 130 ) which are circumferentially distributed, and which are axially recessed and/or axially protruded from a first axial surface ( 115 a ) and/or a second axial surface ( 115 b ) of the disk-shaped main body ( 110 ).
13. The rotor ( 10 ) of claim 12 , wherein the holding structure ( 60 ) is in a positive locking engagement with the three or more fixation structures ( 130 ).
14. An axial flux motor ( 1 ) for a high-volt fan ( 3 ) comprising:
a housing ( 200 ),
a shaft ( 70 ) which is rotatably supported in the housing ( 200 ),
at least one stator ( 80 ) fixedly arranged in the housing ( 200 ), and
a rotor ( 10 ) of claim 1 , wherein the rotor ( 10 ) is fixedly arranged on the shaft ( 70 ) and adjacent to the at least one stator ( 80 ).
15. A high-volt fan ( 3 ) for a vehicle, comprising:
an axial flux motor ( 1 ) of claim 14 , and
a fan wheel ( 2 ) which is fixedly arranged on the shaft ( 70 ) outside the housing ( 200 ).
16. A method for manufacturing the rotor ( 10 ) of claim 1 ,
wherein the holding structure ( 60 ) is formed by injection molding a mold material around the rotor wheel ( 100 ) and the plurality of permanent magnets ( 50 ).
17. The rotor ( 10 ) of claim 1 , wherein the arm tip ( 123 ) is arranged at a radial position between 0.2 and 0.8 of the radial length ( 52 ) of the permanent magnet ( 50 ).
18. A rotor ( 10 ) for an axial flux motor ( 1 ) comprising:
a rotor wheel ( 100 ) comprising:
a disk-shaped main body ( 110 ) defining an inner circumference ( 111 ) and an outer circumference ( 114 ), and
a plurality of arms ( 120 ) protruding from the outer circumference ( 114 ) radially outwards to a respective arm tip ( 123 ), wherein the plurality of arms ( 120 ) is circumferentially distributed on the outer circumference ( 114 ),
a plurality of permanent magnets ( 50 ) distributed circumferentially about the outer circumference ( 114 ) and arranged circumferentially between the plurality of arms ( 120 ), and
a holding structure ( 60 ) being attached to the rotor wheel ( 100 ) and to the plurality of permanent magnets ( 50 ) to hold the plurality of permanent magnets ( 50 ) in position, wherein each of the plurality of arms ( 120 ) has an arm length ( 122 ) in the radial direction ( 24 ), an arm height ( 125 ) in the axial direction ( 22 ) and an arm width ( 126 ) orthogonally to the arm length ( 122 ) and arm height ( 125 ), and wherein at least in a circumferentially outer region ( 113 a ) of the disk-shaped main body ( 110 ), the arm height ( 125 ) is larger than an axial thickness of the disk-shaped main body ( 110 ) such that the arm ( 120 ) extends radially inward from the outer circumference ( 114 ) while protruding axially from the disk-shaped main body ( 110 ).