Inorganic silicon material stator disc with prefabricated winding grooves and motor
By prefabricating winding grooves on an inorganic silicon stator disk and combining them with microfluidic channels and potting materials, the bottlenecks in the electrical, thermal, and mechanical properties of stator materials were solved, enabling a high-efficiency motor design with excellent electromagnetic performance and thermal management capabilities.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-28
- Publication Date
- 2026-03-27
AI Technical Summary
The stator materials of existing axial flux motors have bottlenecks in electrical, thermal and mechanical properties, resulting in low current carrying capacity, poor heat dissipation, poor mechanical rigidity, high vibration and noise, and difficult processing, making it difficult to achieve high current, high rigidity, precise heat dissipation and low-cost manufacturing.
The stator disk is made of inorganic silicon material through melting and sintering. Pre-made winding grooves are formed and microfluidic channels are pressed in the grooves. Combined with high thermal conductivity insulating potting material to fill the windings, a tightly integrated whole structure is formed, realizing high-precision winding groove and active heat dissipation design.
It achieves high rigidity, low torque pulsation, low noise, excellent heat dissipation and strong overload capacity. The air gap design is less than 0.2mm, which significantly improves motor efficiency and torque constant, eliminates the risk of howling and vibration, and has extremely high electromagnetic performance and thermal management capabilities.
Smart Images
Figure CN121749567A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to small or micro electric machines, and in particular to a stator disc of pre-fabricated inorganic silicon material and an electric machine. BACKGROUND
[0002] Axial flux electric machines (especially coreless PCB electric machines) are attracting much attention due to their flat structure. The stator of such machines usually uses a printed circuit board (PCB) with etched copper foil as the winding. However, this design, which follows the ideas of the electronics industry, has some inherent physical limitations in the field of electric machines as the "power core": Electrical performance bottleneck: The thickness of the PCB copper foil is limited, and its current-carrying capacity is extremely low, which limits the power and torque of the electric machine; Thermal performance bottleneck: FR-4 and other organic substrates not only have poor temperature resistance (~130℃), but are also poor thermal conductors, leading to heat accumulation, which is a major cause of electric machine burnout.
[0003] Mechanical performance bottleneck: The mechanical rigidity of the PCB substrate is poor and prone to deformation. This leads to two problems: First, air gap compromise: To prevent the collision (scanning bore) of the stator and rotor at high speed due to deformation, a large safety air gap (such as 0.5mm or more) must be reserved, which severely sacrifices the magnetic field strength and efficiency of the electric machine.
[0004] Vibration and noise: The electromagnetic force under high-frequency current can cause micro-vibration of the conductors on the flexible substrate, generating electromagnetic noise and causing metal fatigue.
[0005] Technical bias and design dilemma: In the prior art, inorganic materials such as inorganic silicon are known for their "high temperature resistance", but are also known for their "poor thermal conductivity", "difficult processing", and "brittleness". Therefore, in the general understanding of those skilled in the art, placing the high-heat-generating winding directly into the inorganic silicon body with poor thermal conductivity is like "self-ensnaring", which will only worsen the heat dissipation problem. At the same time, precise slotting of complex paths on a hard sintered inorganic silicon body is extremely costly and has no commercial value.
[0006] Due to the above multiple physical limitations and technical biases, the field has long been unable to develop a stator solution that can simultaneously solve the problems of large current, high rigidity, precise heat dissipation, and low-cost manufacturing. SUMMARY
[0007] The present application aims to provide a breakthrough in the design and manufacturing of stators. It overcomes all the bottlenecks in the background art through the synergistic design of specific processes and structures, thereby obtaining an electric machine stator and electric machine that has far superior comprehensive performance in the fields of force, heat, and electricity.
[0008] The application is implemented by a stator disc of inorganic silicon material with preformed winding grooves, which is formed by melting and sintering of inorganic silicon material, and the surface of the stator disc is provided with grooves adapted to the winding direction, and the grooves are pressed in one time by using a precision mold in the "green body" state before high-temperature sintering after pressing of inorganic silicon powder, or in the plastic state of glass in the molten / semi-molten state, and then the sintered grooves are formed.
[0009] The stator disc of inorganic silicon material with preformed winding grooves is further pressed with micro-fluid channels or turbulence ribs on the contact surface between the grooves and the winding after the grooves are pressed.
[0010] A motor using a stator disc of inorganic silicon material with preformed winding grooves, which includes a stator and a rotor, and the stator uses the stator disc, and the winding of the stator uses flat copper wire or litz wire.
[0011] The motor using the stator disc of inorganic silicon material with preformed winding grooves has an air gap between the stator and the rotor less than or equal to 0.2 mm.
[0012] Any of the motors using the stator disc of inorganic silicon material with preformed winding grooves, and the stator is filled with a high-thermal-conductivity and high-insulation potting material to completely fill the winding and the gap, and the winding, the disc body and the micro-channel are tightly combined into a solid whole.
[0013] The application overcomes the technical prejudice of the prior art on the material of the stator disc by a special forming process, unexpected material and carefully designed winding cooling design, and good technical effects are achieved. Specifically, it includes: First, the synergy of manufacturing process and structural precision realizes the nonlinear leap of electromagnetic performance of the motor. The prior art considers that inorganic silicon is difficult to process, but the application bypasses the problem of "hard processing" and obtains micron-level winding slot precision at a very low cost through the idea of "soft processing and hard solidification". This precision brings two breakthroughs: ultra-low torque ripple: extremely high winding position consistency ensures the high symmetry of the magnetic field, significantly reduces the torque ripple and vibration noise, which is difficult for PCB or traditional winding process to achieve. Smaller air gap design is possible: the high mechanical rigidity (almost no deformation) and high precision of the inorganic silicon disc allow designers to confidently reduce the stator-rotor air gap from the traditional 0.5 mm or more to 0.2 mm or even smaller, without reserving a large safety margin for deformation. According to electromagnetic principles, the reduction of air gap can make the magnetic flux density increase in a square inverse proportion, thereby sharply increasing the torque constant (Nm / A) and efficiency of the motor in a nonlinear way. This is a huge gain that cannot be foreseen and achieved by simply combining "using inorganic silicon" or "opening a groove".
[0014] Second, the groove structure turns "poor heat dissipation body" into "high-efficiency three-dimensional heat dissipation system", overcoming the technical prejudice in the field. The invention directly faces the technical prejudice of "poor heat conduction of inorganic silicon" and completely overturns it by using the groove structure. Passive heat dissipation is changed to active heat dissipation: through the integrally formed "micro-fluid channel", the cooling medium (such as water or air) can be directly introduced to the "epicenter" of heat - the position close to the copper wire, realizing "source type" accurate and efficient heat dissipation. Its heat dissipation efficiency is much higher than that of indirect cooling from the outside of the motor. This makes it possible to achieve excellent heat dissipation effect even with inorganic silicon of general thermal conductivity such as aluminum oxide. A new design dimension is provided: the groove structure of the invention turns a 2D heat dissipation problem into a 3D actively designed heat management engineering. Designers can flexibly arrange the path and density of the micro-channel to realize customized heat management scheme. This is completely unimaginable for flat PCB or unslotted solid inorganic silicon disc.
[0015] Third, high stability and super overload capacity under multi-physical field coupling. The structure of the invention shows excellent performance under the coupling of force, heat and electricity.
[0016] Elimination of whistling and vibration: the wire is completely "locked" by the rigid groove and the potting glue, which physically eliminates the micro-vibration of the wire under high-frequency electromagnetic force, and eliminates the risk of electromagnetic whistling and fatigue fracture from the root.
[0017] Unparalleled peak overload capacity: when the motor is instantaneously overloaded and the current surges, it will generate a lot of heat and electromagnetic impact force at the same time. In the invention: 1) the solid inorganic silicon groove wall provides strong mechanical support for the wire to resist impact force; 2) the high temperature resistance of inorganic silicon provides a valuable time window for heat diffusion. This "force-heat" double insurance makes the motor can withstand instantaneous impact far exceeding its rated power without any damage, which is unmatched by any existing stator structure. BRIEF DESCRIPTION OF DRAWINGS
[0018] The invention will be further described below in conjunction with the drawings: Figure 1 is a molded stator disc schematic diagram; Figure 2 is a schematic diagram of the motor. DETAILED DESCRIPTION
[0019] Please refer to Figure 1A stator disc of inorganic silicon material with preformed winding grooves, which is made by melting and sintering of inorganic silicon material, the surface of the stator disc 1 is provided with grooves adapted to the winding 11, the stator disc is pressed in inorganic silicon powder, before high temperature sintering, i.e. in the "green body" state, or in the plastic state of the glass in the molten / semi-molten state, using a precision mold to press the grooves in one step, then sintering and setting. The inorganic silicon material includes: ceramic (such as alumina, aluminum nitride) or glass (such as quartz glass, microcrystalline glass). Fig. a is the winding into the line head, b is the winding out of the line head.
[0020] The stator disc of inorganic silicon material with preformed winding grooves, after pressing the grooves in accordance with the winding path, further pressing the microfluid channel or turbulence rib 12 in the groove and the contact surface of the winding. Fig. c is the fluid inlet, d is the fluid outlet.
[0021] Please refer to Figure 1 and Figure 2 A motor using a stator disc of inorganic silicon material with preformed winding grooves, which includes a stator 2 and a rotor 3, the stator uses the stator disc, and the winding of the stator uses flat copper wire or litz wire.
[0022] The motor using a stator disc of inorganic silicon material with preformed winding grooves, the stator-rotor air gap is less than or equal to 0.2mm.
[0023] Any of the motor using a stator disc of inorganic silicon material with preformed winding grooves, the stator uses high thermal conductivity, high insulation of the potting material to fill the winding and the gap completely, the winding, disc body, microchannel are tightly combined into a solid whole.
[0024] The motor is tested according to the enterprise standard of this application, the insulation resistance (cold state) is greater than 2.5MΩ; hot state is greater than 2MΩ; 1800V withstand voltage test is qualified, the temperature of the rolling bearing under the rated voltage working condition is less than 50℃; the shell temperature is not more than 50℃; overspeed test, 1.5 times the highest speed 150 seconds, no any deformation, short time over torque test 2 times the rated current 150 seconds without damage.
Claims
1. A stator disk made of inorganic silicon material with pre-formed winding grooves, wherein the surface of the stator disk is provided with grooves adapted to the winding direction, characterized in that, The stator disk is made by melting and sintering inorganic silicon material. That is, after the inorganic silicon powder is pressed and before high-temperature sintering, in the "green" state, or in the molten / semi-molten plastic state of the glass, the grooves that conform to the winding path are pressed out in one go using a precision mold, and then sintered to shape.
2. The stator disk of inorganic silicon material with prefabricated winding grooves according to claim 1, characterized in that, After pressing out the grooves that conform to the winding path, microfluidic channels or turbulence ribs are further pressed in the grooves and on the winding contact surface.
3. A motor employing a stator disc of inorganic silicon material with prefabricated winding grooves, comprising a stator and a rotor, characterized in that, The stator uses the aforementioned stator disk, and the stator windings use flat copper wire or Litz wire.
4. A motor using an inorganic silicon material stator disc with prefabricated winding grooves according to claim 3, characterized in that, The air gap between the stator and rotor is less than or equal to 0.2 mm.
5. The motor using an inorganic silicon stator disc with prefabricated winding grooves according to any one of claims 3 or 4, characterized in that, The stator uses a high thermal conductivity and high insulation potting material to completely fill the windings and gaps, tightly combining the windings, disk, and microchannels into a robust whole.