Enhanced coreless stator and coreless disc type motor

Abstract

The enhanced coreless stator comprises a substrate, a stator winding is arranged on the substrate, the stator winding comprises an effective conductor section for cutting axial magnetic flux, the effective conductor section is in a sheet shape, and the main plane of the effective conductor section is not parallel to the plate surface of the substrate. According to the coreless stator, the relative position relation between the effective conductor sections and the substrate is changed, so that the single effective conductor section has a traditional current flowing cross section and also has higher resistance to magnetic acting force, and the coreless stator is higher in structural strength and more stable in operation. Meanwhile, the occupied area of the axial projection of the sheet-shaped effective conductor section on the substrate is small, and more stator windings can be distributed on the substrate with the same area. The single-turn structural strength and the number of turns per unit area are synchronously improved, the overall structural strength of the stator is remarkably enhanced, meanwhile, the energy density of the motor is improved, and higher power output is achieved.

Description

Technical Field

[0001] This invention relates to the field of motor technology, and in particular to an enhanced coreless stator and a coreless disc motor. Background Technology

[0002] Coreless disc motors, with their advantages of small size, light weight, and high torque and power density, have become core drive components in high-end fields such as aerospace, electric vehicles, wind power generation, robotics, and CNC machine tools. However, their stator structure has long faced the bottleneck of balancing "lightweight" and "high strength": the traditional method of directly laying the winding coils on the disc and gluing them together results in poor wiring consistency, many manual steps, and makes it impossible to achieve large-scale, automated production; while the PCB board stators that have emerged in recent years can use mature photolithography-etching technology to form the windings in one step within a multi-layer printed circuit board, resulting in high production efficiency and good consistency, but they have also exposed new mechanical shortcomings.

[0003] The PCB substrate is primarily composed of epoxy resin-glass fiber composite material, which has a low elastic modulus and weak bending resistance. While the surface copper foil can serve as conductive traces and a local reinforcing layer, its thickness is typically only 18-35µm, far less than what is required for structural load-bearing capacity. To reduce winding resistance, the design necessitates increasing the copper foil linewidth, resulting in the copper foil's main plane being perpendicular to the motor's axis. The alternating electromagnetic force generated by the axial magnetic flux acts directly perpendicularly on the copper foil surface, leading to extremely poor bending stiffness and susceptibility to plastic deformation. Simultaneously, the increased linewidth compresses the effective number of turns, reducing the number of turns per unit area and further weakening the overall reinforcing effect of the copper foil on the substrate. Consequently, the PCB stator exhibits significant axial warping and radial jitter during high-speed, high-load operation, distorted air gap magnetic field distribution, a dramatically increased risk of copper foil fatigue cracking, a sharp drop in motor energy conversion efficiency, and difficulty in achieving high-power, long-life operation. Summary of the Invention

[0004] The first objective of this invention is to provide an enhanced coreless stator.

[0005] The technical solution to achieve the purpose of this invention is: an enhanced coreless stator, comprising a substrate, the substrate comprising one or more stacked single plates, a stator winding disposed on the substrate, the stator winding comprising an effective conductor segment for cutting axial magnetic flux, the effective conductor segment being sheet-shaped, and the principal plane of the effective conductor segment being non-parallel to the plate surface of the substrate.

[0006] Furthermore, the main plane of the effective conductor segment is perpendicular to the substrate surface. When the main plane of the effective conductor segment is perpendicular to the substrate surface, the surface of the effective conductor segment is parallel to the axial magnetic field force. The axial magnetic field force acts entirely on the effective conductor segment in a direction parallel to the plane of the effective conductor segment. Since the bending resistance is stronger in the direction parallel to the plane of the effective conductor segment, the structural strength is higher, and the deformation resistance of the effective conductor segment is stronger. Moreover, after the plane of the effective conductor segment is perpendicular to the plane of the substrate, the area occupied by each effective conductor segment on the substrate is smaller, the placement density of the effective conductor segments on the substrate is higher, and the number of effective conductor segments that can be placed on the same area substrate is greater. The greater number of effective conductor segments on the substrate and the more significant the reinforcing effect, the stronger the structural strength of the substrate and the greater its energy density.

[0007] Furthermore, the angle α between the main plane of the effective conductor segment and the substrate surface satisfies the following relationship: 45° < α < 90°, and the projection portions of any two adjacent effective conductor segments on the substrate overlap. When the effective conductor segment is inclined relative to the substrate, although the resistance of a single effective conductor segment to axial magnetic field force is not as strong as that of an effective conductor segment perpendicular to the substrate, at an angle of 45° < α < 90°, the resistance of a single effective conductor segment to axial magnetic field force is much stronger than that of an effective conductor segment parallel to the substrate. In other words, under the above configuration, a single effective conductor segment has a certain and relatively strong resistance to axial magnetic field force. Based on this, the overlapping horizontal projection portions of any two adjacent effective conductor segments allow the circumferential area of ​​all the inclined effective conductor segments projected onto the substrate to form a ring, resulting in a more continuous and uniform circumferential distribution of the reinforcing effect of the effective conductor segments on the substrate. The single effective conductor segment has strong resistance, and the reinforcing effect of all the effective conductor segments on the substrate is continuously and uniformly distributed in the circumferential direction, ultimately resulting in a strong reinforcing effect at any point in the circumferential direction of the substrate, without any weak points. The overall structure of the substrate has higher strength and better stability.

[0008] Furthermore, the substrate has strip-shaped grooves, each corresponding to a valid conductor segment, which is fixed within the groove. The length of the groove matches the length of the valid conductor segment, and the width matches the thickness of the valid conductor segment. The valid conductor segment can be directly fixed to the surface of the substrate, or the groove can be formed on the substrate to fix it within the groove. Compared to the former, the latter method allows the groove to position the valid conductor segment, facilitating quick determination of the installation position. Furthermore, the valid conductor segment, surrounded and limited by the substrate, is deeply connected to the substrate, resulting in a more robust and reliable fixing structure.

[0009] Furthermore, the strip-shaped groove extends vertically through the substrate surface. This arrangement allows the effective conductor segment to protrude beyond both sides of the substrate during installation. Thus, on one hand, the two surfaces of the substrate with the strip-shaped groove extending through them have identical structures, with no distinction between front and back, facilitating the installation of the effective conductor segment; on the other hand, the effective conductor segment protruding beyond both sides of the substrate allows for heat dissipation from both sides, facilitating the outward dissipation of heat from the effective conductor segment.

[0010] Furthermore, the substrate is coaxially provided with an annular through hole, and the strip groove is located on the annular through hole. Each strip groove is divided into a first end and a second end by the annular through hole, with the first end and the second end located on the substrate on both sides of the annular through hole. The substrate can be a single unit, with the strip groove formed on the substrate. After the annular through hole is provided, the substrate can also be divided into coaxial inner and outer parts. In this structure, the strip groove is also divided into a first end and a second end by the annular through hole, with the first end and the second end located on the outer edge of the inner part of the substrate and the inner edge of the outer part of the substrate, respectively. Compared to the former, the annular through hole in the latter allows the substrate to be lighter; furthermore, it makes it easier to process the first end and the second end located on the outer edge of the inner part of the substrate and the inner edge of the outer part of the substrate, making the formation of the strip groove more convenient.

[0011] Furthermore, the substrate is provided with a mounting portion for connection and fixation to the motor housing. A plurality of insulating heat dissipation ribs are mounted on the surface of the substrate. One end of each insulating heat dissipation rib is connected to the effective conductor segment, and the other end extends to the mounting portion of the substrate. The enhanced coreless stator of the present invention, by providing the insulating heat dissipation ribs on the substrate, with one end connected to the effective conductor segment and the other end extending to the mounting portion of the substrate, utilizes the insulating heat dissipation ribs to conduct heat energy from the effective conductor segment to the motor housing fixed to the enhanced coreless stator of the present invention at the mounting portion. This allows for heat dissipation outside the motor housing via fins, air cooling, or water cooling. This invention relates to an enhanced coreless stator. Inside the motor, the insulating heat dissipation fins conduct heat from the effective conductor segment to the motor housing at the mounting location. Compared to air or the substrate, the insulating heat dissipation fins have a higher thermal conductivity. Furthermore, the insulating heat dissipation fins are directly connected to the effective conductor segment, which is the main heat-generating component. The heat generated on the effective conductor segment is directly discharged through the insulating heat dissipation fins, resulting in a short heat dissipation path. This combination of high thermal conductivity and a short heat dissipation path leads to low thermal resistance, allowing for rapid heat dissipation from the effective conductor segment and significantly improving the motor's heat dissipation efficiency. While maintaining the advantages of being coreless, ultra-thin, and lightweight, this invention overcomes the bottleneck of traditional coreless motor heat dissipation difficulties, enabling the entire coreless stator and motor to achieve highly efficient heat dissipation. With the power density of motors increasing exponentially and the heat flux density correspondingly increasing for the same volume, the highly efficient heat dissipation structure of this invention ensures stable operation of high-power-density motors in continuous industrial production, further guaranteeing the large-scale implementation of this invention.

[0012] Furthermore, the mounting portion is located at the outer peripheral edge of the substrate or the inner peripheral edge of the substrate.

[0013] Furthermore, a reinforcing ring is coaxially mounted on the mounting portion of the substrate, and the end of the insulating heat dissipation rib extending to the mounting portion is connected to the reinforcing ring. During operation, the heat of the effective conductor segment is conducted to the mounting portion via the insulating heat dissipation rib, and then conducted to the motor housing via the reinforcing ring for heat dissipation, forming a heat conduction path of effective conductor segment → insulating heat dissipation rib → reinforcing ring → motor housing. The reinforcing ring enhances the overall structure of the stator, especially since the structural strength at the edge of the substrate is usually weak, and the mounting portion is typically located at the edge of the substrate. The reinforcing ring strengthens the edge structure of the substrate. Furthermore, given the large number of insulating heat dissipation ribs, connecting each rib individually to the motor housing to form a heat conduction path is cumbersome. The reinforcing ring facilitates the compression connection of the numerous insulating heat dissipation ribs, subsequently facilitating the connection of the reinforced coreless stator of this invention to the motor housing, thus achieving heat conduction from the insulating heat dissipation rib to the motor housing.

[0014] Furthermore, insulating heat dissipation ribs are distributed on both sides of the substrate. The insulating heat dissipation ribs can be provided on one side of the substrate for single-sided heat dissipation; alternatively, the insulating heat dissipation ribs can be provided on both sides of the substrate for double-sided heat dissipation. Compared to the former, double-sided heat dissipation provides a larger heat dissipation surface and better heat dissipation effect.

[0015] Furthermore, each effective conductor segment has insulating heat dissipation ribs distributed on both ends, with each end of the effective conductor segment connected to a corresponding insulating heat dissipation rib. During operation, heat on the effective conductor segment is simultaneously dissipated through the insulating heat dissipation ribs on both ends. Compared to a structure where the insulating heat dissipation rib is only located at one end of the effective conductor segment, the structure with insulating heat dissipation ribs on both ends allows for a larger heat conduction surface, faster and more timely heat dissipation, and more uniform heat dissipation from the effective conductor segment.

[0016] Furthermore, mounting portions are provided on both the outer and inner peripheral edges of the substrate. Each effective conductor segment has corresponding insulating heat dissipation ribs distributed at both ends. One end of each insulating heat dissipation rib is connected to the end of the effective conductor segment closest to it, and the other end extends to the mounting portion closest to it and connects to the reinforcing ring. With this configuration, both the inner and outer peripheral edges of the substrate are fixedly connected to the motor housing. The reinforcement from the motor housing further strengthens the structural strength of the inner and outer peripheral edges of the substrate. Moreover, the ends of the insulating heat dissipation ribs extend close to the mounting portion, resulting in a shorter heat conduction path, a higher heat dissipation speed, and higher heat dissipation efficiency.

[0017] Furthermore, the substrate has a circular ring structure, the effective conductor segment is a strip-shaped sheet, and the insulating heat dissipation rib is strip-shaped; all the effective conductor segments on the substrate are distributed in a radiating pattern, and the length direction of the insulating heat dissipation rib is aligned with the length direction of the effective conductor segment. To achieve uniform distribution, the effective conductor segments are typically distributed in a radiating pattern. The alignment of the length direction of the insulating heat dissipation rib with the length direction of the effective conductor segment reduces the heat conduction path.

[0018] Furthermore, the single-layer board is a polymer composite board, such as a composite board made of epoxy, glass fiber, etc. Polymer composite boards have high structural strength, making them suitable for high-power applications.

[0019] Furthermore, the substrate contains two or more single-layer boards. The substrate contains two or more single-layer boards, and a strip-shaped groove is formed on the substrate. When the strip-shaped groove extends through the plane of the substrate in the vertical direction, the same effective conductor segment axially passes through all the single-layer boards in all layers, achieving axial continuity. With this structure, on the one hand, the same effective conductor segment strings together the single-layer boards of all layers, enhancing the strength of the connection structure of the single-layer boards in all layers; on the other hand, the uninterrupted arrangement of the effective conductor segment along the axial direction of the substrate also provides the maximum dimension of the effective conductor segment in that direction, enabling the effective conductor segment to have a larger current cross-section and current density, achieving higher power output.

[0020] The second objective of this invention is to provide a coreless disc motor.

[0021] A coreless disc motor includes an enhanced coreless stator, a rotor, a shaft, and a motor housing, as described in this invention. The shaft is rotatably mounted on the motor housing. The enhanced coreless stator and the rotor are located inside the motor housing. There are two rotors, each located on one side of the enhanced coreless stator. The rotors are fixedly mounted on the shaft, and the enhanced coreless stator is rotatably mounted on the shaft. The enhanced coreless stator is fixedly connected to the motor housing.

[0022] This invention relates to an enhanced coreless stator and a coreless disc motor. The enhanced coreless stator of this invention arranges the principal plane of the effective conductor segment, which is plate-shaped, non-parallel to the substrate surface. This allows it to cut magnetic flux within an axial magnetic field. When subjected to axial magnetic force, this force acts non-perpendicularly on the principal plane of the effective conductor segment, with at least a partial component in the direction parallel to the principal plane. In the plate-shaped structure, the resistance to force is strong in the direction parallel to the principal plane of the effective conductor segment, but weak in the direction perpendicular to it. Compared to the traditional structure where the effective conductor segment is perpendicular to the axial force, and the axial force acts entirely in the direction where the resistance of the principal plane is weak, in this invention, at least a partial component of the axial force acts in the direction parallel to the principal plane of the effective conductor segment, where the resistance is strong. The stronger resistance in the direction parallel to the principal plane of the effective conductor segment resists at least a partial component of the axial force, resulting in less effective axial bending force on the effective conductor segment and higher overall stator structural strength.

[0023] This invention relates to an enhanced coreless stator and a coreless disc motor. While maintaining the same structure as the traditional effective conductor segment, it alters the relative position of the effective conductor segment and the substrate. This allows each effective conductor segment to possess both the traditional current-carrying cross-section and greater resistance to magnetic forces, resulting in stronger structural strength. Furthermore, by non-parallelizing the plane of the effective conductor segment with the plane of the substrate, the axial projection area of ​​the effective conductor segment on the substrate is smaller. This allows for a greater number of stator windings to be distributed on the same area of ​​substrate, increasing the number of turns per unit area of ​​the effective conductor segment. The stronger structural strength of a single-turn effective conductor segment and the higher number of turns per unit area simultaneously improve both single-turn structural strength and the number of turns per unit area. Ultimately, this significantly enhances the overall structural strength of the coreless stator, greatly improves its resistance to magnetic forces, and makes it more stable in operation, adaptable to high-power, long-life conditions. Simultaneously, the motor's energy density is significantly increased, achieving higher power output. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of the enhanced coreless stator of the present invention; Figure 2 for Figure 1 A magnified structural diagram of part A in the middle; Figure 3 This is a cross-sectional view of one end of the effective conductor segment of the enhanced coreless stator of the present invention; Figure 4 This is a schematic diagram of another embodiment of the stator winding of the enhanced coreless stator of the present invention; Figure 5This is a schematic diagram of another embodiment of the insulating heat dissipation fin of the present invention; Figure 6 This is a schematic diagram of the assembly structure of the coreless disc motor of the present invention. Detailed Implementation

[0025] The preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0026] like Figures 1 to 3 As shown, an enhanced coreless stator includes a substrate 1, which includes one or more stacked single plates 10. A stator winding 2 is arranged on the substrate 1. The stator winding 2 includes an effective conductor segment 21 that cuts axial magnetic flux. The effective conductor segment 21 is sheet-shaped, and the main plane of the effective conductor segment 21 is not parallel to the plate surface of the substrate 1.

[0027] This invention relates to an enhanced coreless stator, with the substrate 1 serving as the stator carrier. The stator winding 2, composed of conductor coils, is one of the main components of the motor. The stator winding 2 includes an effective conductor segment 21 and an end conductor segment 22, which are spaced apart and connected end-to-end to form a closed loop. The effective conductor segment 21 is located within the magnetic field region and cuts the axial magnetic flux, while the end conductor segment 22 is located outside the magnetic field region and its contribution to torque is negligible.

[0028] This invention relates to an enhanced coreless stator, wherein the effective conductor segment 21 is sheet-shaped. The plane containing the main plane of the effective conductor segment 21 is not parallel to the plane containing the substrate 1; it can be inclined or perpendicular. The angle α between the main plane of the effective conductor segment and the substrate 1 is 0 < α ≤ 90°, such as α being 5°, 10°, 25°, 35°, 50°, 75°, 90°, etc. When the main plane of the effective conductor segment 21 is inclined to the substrate 1, the direction of the axial magnetic field is also inclined. The axial magnetic force acts obliquely on the main plane of the effective conductor segment 21. Part of this axial magnetic force is decomposed into a direction parallel to the main plane of the effective conductor segment 21, and another part is decomposed into a direction perpendicular to the main plane of the effective conductor segment 21. When the principal plane of the effective conductor segment 21 is perpendicular to the plane of the substrate 1, the principal plane of the effective conductor segment 21 is parallel to the direction of the axial magnetic field, and the axial magnetic force acts on the effective conductor segment 21 in a direction parallel to the principal plane of the effective conductor segment 21. This axial magnetic force is entirely in the direction parallel to the plane of the effective conductor segment 21.

[0029] The enhanced coreless stator of this invention is installed on the motor and interacts with the axial magnetic field to achieve electromagnetic coupling and complete the motor function.

[0030] This invention relates to an enhanced coreless stator in which the main plane of the sheet-like effective conductor segment 21 is not parallel to the surface of the substrate 1. This allows it to cut magnetic flux within an axial magnetic field. When subjected to axial magnetic force, this force acts non-perpendicularly on the main plane of the effective conductor segment 21, with at least a partial component in the direction parallel to the main plane. In this sheet-like structure, the effective conductor segment 21 exhibits strong resistance to force in the direction parallel to its main plane, but weak resistance in the direction perpendicular to it. Compared to the traditional structure where the effective conductor segment is perpendicular to the axial force, and the axial force acts entirely in the direction where the resistance of the main plane is weak, this invention allows at least a partial component of the axial force to act in the direction parallel to the main plane of the effective conductor segment, where resistance is stronger. This stronger resistance in the direction parallel to the main plane resists at least a partial component of the axial force, resulting in less effective axial bending force on the effective conductor segment 21 and higher overall stator structural strength.

[0031] This invention relates to an enhanced coreless stator. While maintaining the same structure as a traditional effective conductor segment, it alters the relative position of the effective conductor segment 21 to the substrate 1. This allows each effective conductor segment 21 to possess both a traditional current-carrying cross-section and greater resistance to magnetic forces, resulting in stronger structural strength. Furthermore, by non-parallelizing the plane of the sheet-like effective conductor segment 21 to the plane of the substrate 1, the axial projection area of ​​the effective conductor segment 21 on the substrate 1 is smaller. This allows for a greater number of stator windings 2 to be distributed on the same area of ​​the substrate 1, increasing the number of turns of the effective conductor segment 21 per unit area. The increased structural strength per turn and the higher number of turns per unit area demonstrate that this invention simultaneously improves both single-turn structural strength and the number of turns per unit area, ultimately leading to a significant enhancement in the overall structural strength of the coreless stator. This significantly improves its resistance to magnetic forces, resulting in more stable operation and adaptability to high-power, long-life conditions. Simultaneously, it significantly increases the motor's energy density, enabling higher power output.

[0032] A first embodiment of the enhanced coreless stator of the present invention, as follows: Figure 2 and Figure 3As shown, the main plane of the effective conductor segment 21 is perpendicular to the surface of the substrate 1. When the main plane of the effective conductor segment 21 is perpendicular to the surface of the substrate 1, the surface of the effective conductor segment 21 is parallel to the axial magnetic field force. The axial magnetic field force acts completely on the effective conductor segment 21 in a direction parallel to the plane of the effective conductor segment 21. Since the bending resistance is stronger in the direction parallel to the plane of the effective conductor segment, the structural strength is higher, and the deformation resistance of the effective conductor segment 21 is stronger. Furthermore, after the plane of the effective conductor segment 21 is perpendicular to the plane of the substrate 1, the area occupied by each effective conductor segment 21 on the substrate 1 is smaller, and the arrangement density of the effective conductor segments 21 on the substrate 1 is higher. The number of effective conductor segments 21 on the substrate 1 is greater, the reinforcing effect is more significant, and the structural strength of the substrate 1 is stronger, while the energy density is also greater.

[0033] A second embodiment of the enhanced coreless stator of the present invention, as follows: Figure 4 As shown, the angle α between the main plane of the effective conductor segment 21 and the surface of the substrate 1 satisfies the following relationship: 45° < α < 90°, and the projection portions of any two adjacent effective conductor segments 21 on the substrate overlap. When the effective conductor segment 21 is inclined relative to the substrate 1, although the resistance of a single effective conductor segment 21 to axial magnetic field force is not as strong as that of an effective conductor segment 21 perpendicular to the substrate 1, at an angle of 45° < α < 90°, the resistance of a single effective conductor segment 21 to axial magnetic field force is much stronger than that of an effective conductor segment 21 parallel to the substrate 1. In other words, under the above arrangement, a single effective conductor segment 21 has a certain and relatively strong resistance to axial magnetic field force. Based on this, the horizontal projection portions of any two adjacent effective conductor segments 21 overlap, and the circumferential area of ​​all the inclined effective conductor segments 21 projecting onto the substrate 1 can form a ring, and the reinforcing effect of the effective conductor segments 21 on the substrate 1 is continuously and uniformly distributed in the circumferential direction. The single effective conductor segment 21 has strong resistance, and the reinforcing effect of all the effective conductor segments 21 on the substrate 1 is continuously and uniformly distributed in the circumferential direction, ultimately resulting in a strong reinforcing effect at any point in the circumferential direction of the substrate 1, without any weak points. The overall structure of the substrate 1 has higher strength and better stability.

[0034] In this invention, an enhanced coreless stator preferably includes a strip-shaped groove 11 on the substrate 1, with each strip-shaped groove 11 corresponding to an effective conductor segment 21, and the effective conductor segment 21 fixed within the strip-shaped groove 11. The length of the strip-shaped groove 11 is the same as the length of the effective conductor segment 21, and the width of the strip-shaped groove 11 is the same as the thickness of the effective conductor segment 21. The effective conductor segment 21 can be directly fixed to the surface of the substrate 1, or the strip-shaped groove 11 can be formed on the substrate 1, with the effective conductor segment 21 fixedly installed within the strip-shaped groove 11. Compared to the former, when installed within the strip-shaped groove 11, the latter allows the strip-shaped groove 11 to position the effective conductor segment 21, facilitating quick determination of the installation position. Furthermore, the effective conductor segment 21, surrounded and limited by the substrate 1, is deeply connected to the substrate 1, resulting in a more robust and reliable fixing structure.

[0035] In the enhanced coreless stator of the present invention, preferably, the strip groove 11 extends through the vertical direction of the substrate 1. This arrangement has two advantages: firstly, the two surfaces of the substrate 1 with the strip groove 11 extending through both sides have the same structure, with no distinction between front and back, facilitating the installation of the effective conductor segment 21; secondly, the effective conductor segment 21 protrudes beyond the two side surfaces of the substrate 1, allowing heat dissipation from both sides of the substrate 1, thus facilitating the outward dissipation of heat from the effective conductor segment 21.

[0036] In this invention, an enhanced coreless stator preferably has an annular through-hole 12 coaxially arranged on the substrate 1. A strip groove 11 is located on the annular through-hole 12, and each strip groove 11 is divided into a first end 111 and a second end 112 by the annular through-hole 12. The first end 111 and the second end 112 are respectively located on the substrate 1 on both sides of the annular through-hole 12. The substrate 1 can be a single unit, with the strip groove 11 formed on the substrate 1. Alternatively, after the annular through-hole 12 is provided, the substrate 1 can also be divided into coaxial inner and outer parts. In this structure, the strip groove 11 is also divided into a first end 111 and a second end 112 by the annular through-hole 12. The first end 111 and the second end 112 are respectively located on the outer edge of the inner part of the substrate 1 and the inner edge of the outer part of the substrate 1. Compared to the former, the latter's annular through hole 12 makes the substrate 1 lighter on the one hand; on the other hand, it makes it easier to process the first end 111 and the second end 112 on the outer edge of the inner part of the substrate 1 and the inner edge of the outer part of the substrate 1, and the formation of the strip groove 11 is more convenient.

[0037] In the enhanced coreless stator of the present invention, preferably, the substrate 1 is provided with a mounting part 13 for connection and fixation to the motor housing, and a plurality of insulating heat dissipation ribs 3 are also installed on the surface of the substrate 1, one end of each insulating heat dissipation rib 3 is connected to the effective conductor segment 21, and the other end extends to the mounting part 13 of the substrate 1.

[0038] This invention relates to an enhanced coreless stator. The insulating heat-dissipating rib 3 is thermally conductive but non-conductive. One end of the insulating heat-dissipating rib 3 is connected to the effective conductor segment 21, and the other end is located at the mounting portion 11 of the substrate 1. It is used to conduct heat from the effective conductor segment 21 to the motor housing fixed at the mounting portion 11. The insulating heat-dissipating rib 3 is insulated and can be stacked on top of the end conductor segment 22. The insulating heat-dissipating rib 3 and the end conductor segment 22 are positioned independently of each other.

[0039] In this invention, the enhanced coreless stator has an effective conductor segment 21 that cuts and interacts with a magnetic field. During this interaction, the effective conductor segment 21 generates heat, becoming the main heat-generating component of the motor. The heat generated by the effective conductor segment 21 is conducted to the insulating heat dissipation fins 3, then to the mounting portion 11 on the substrate 1, and further to the motor housing connected to the enhanced coreless stator. The motor housing then dissipates heat externally, such as through finned cooling, or by external air or water cooling.

[0040] The enhanced coreless stator of the present invention, by providing the insulating heat dissipation rib 3 on the substrate 1, with one end of the insulating heat dissipation rib 3 connected to the effective conductor segment 21 and the other end extending to the mounting part 13 of the substrate 1, conducts the heat energy on the effective conductor segment 21 to the motor housing fixed to the mounting part 13 of the present invention, thereby enabling heat dissipation outside the motor housing through fins, air cooling, or water cooling.

[0041] This invention relates to an enhanced coreless stator. Inside the motor, the insulating heat dissipation fins 3 conduct heat energy from the effective conductor segment 21 to the motor housing at the mounting part 13. Compared to air conduction or the heat conduction of the substrate 1, the insulating heat dissipation fins 3 have a higher thermal conductivity. Furthermore, the insulating heat dissipation fins 3 are directly connected to the effective conductor segment 21, which is the main heat-generating component. The heat energy generated on the effective conductor segment 21 is directly discharged through the insulating heat dissipation fins 3, resulting in a short heat dissipation path. With the dual features of high thermal conductivity and short heat conduction path, the thermal resistance for heat dissipation is low, allowing for rapid heat dissipation from the effective conductor segment 21, greatly improving the motor's heat dissipation efficiency. While maintaining the advantages of being coreless, ultra-thin, and lightweight, this invention overcomes the bottleneck of traditional coreless motor heat dissipation difficulties, enabling the entire coreless stator and motor to achieve highly efficient heat dissipation. With the power density of motors increasing exponentially and the heat flux density of the same volume correspondingly increasing, the highly efficient heat dissipation structure of this invention ensures the stable operation of high-power-density motors in continuous industrial production, further guaranteeing the large-scale implementation of this invention.

[0042] During motor assembly, the mounting portion 13, which is connected and fixed to the motor housing, is typically located at the outer peripheral edge or the inner peripheral edge of the base plate 1. Therefore, depending on the specific motor structure design, in the enhanced coreless stator of the present invention, the mounting portion 13 can be located at either the outer peripheral edge or the inner peripheral edge of the base plate 1. Alternatively, the mounting portion 13 can be provided on both the outer peripheral edge and the inner peripheral edge of the base plate 1.

[0043] In the enhanced coreless stator of the present invention, preferably, a reinforcing ring 4 is coaxially mounted on the mounting portion 13 of the substrate 1, and the end of the insulating heat dissipation rib 3 extending to the mounting portion 13 is connected to the reinforcing ring 4. During operation, the heat of the effective conductor segment 21 is conducted to the mounting portion 13 via the insulating heat dissipation rib 3, and then conducted to the motor housing via the reinforcing ring 4 for heat dissipation, forming a heat conduction path of effective conductor segment 21 → insulating heat dissipation rib 3 → reinforcing ring 4 → motor housing. The reinforcing ring 4 serves two purposes. First, it strengthens the overall structure of the stator. In particular, the structural strength at the edge of the substrate 1 is usually weak, and the mounting part 13 is typically located at the edge of the substrate 1. By setting the reinforcing ring 4 at the edge of the substrate 1, the edge structural strength of the substrate 1 can be strengthened. Second, the number of insulating heat dissipation ribs 3 is relatively large. Connecting a large number of insulating heat dissipation ribs 3 to the motor housing to form a heat conduction path is cumbersome. The reinforcing ring 4 facilitates the pressing and fastening connection of the large number of insulating heat dissipation ribs 3, which in turn facilitates the connection of the reinforced coreless stator of the present invention to the motor housing, thereby achieving heat conduction from the insulating heat dissipation ribs 3 to the motor housing.

[0044] The present invention provides an enhanced coreless stator, such as... Figure 3 As shown, preferably, the insulating heat dissipation ribs 3 are distributed on both sides of the substrate 1. The insulating heat dissipation ribs 3 can be provided on one side of the substrate 1 for single-sided heat dissipation; or the insulating heat dissipation ribs 3 can be provided on both sides of the substrate 1 for double-sided heat dissipation. Compared to the former, double-sided heat dissipation provides a larger heat dissipation surface and better heat dissipation effect.

[0045] The first embodiment of the insulating heat dissipation fin 3 of the present invention is as follows: Figure 2 The mounting portion 13 is provided on the outer peripheral edge of the substrate 1, and the reinforcing ring 4 is mounted on the mounting portion 13. The outer end of each effective conductor segment 21 is provided with an insulating heat dissipation rib 3. One end of the insulating heat dissipation rib 3 is connected to the outer end of the corresponding effective conductor segment 21, and the other end extends to the mounting portion 13 on the outer peripheral edge of the substrate 1 and is connected to the reinforcing ring 4.

[0046] The second embodiment of the insulating heat dissipation fin 3 of the present invention is as follows: Figure 5 As shown, mounting portions 13 are provided on both the outer and inner peripheral edges of the substrate 1, and reinforcing rings 4 are provided on both mounting portions 13 on the inner peripheral edge. Each effective conductor segment 21 has corresponding insulating heat dissipation ribs 3 distributed at both ends. One end of each insulating heat dissipation rib 3 is connected to the end of the effective conductor segment 21 closest to it, and the other end extends to the mounting portion 13 closest to it and connects to the reinforcing ring 4. That is, the other end of the insulating heat dissipation rib 3 connected to the outer end of the effective conductor segment 21 extends to the mounting portion 13 on the outer peripheral edge of the substrate 1, and the other end of the insulating heat dissipation rib 3 connected to the inner end of the effective conductor segment 21 extends to the mounting portion 13 on the inner peripheral edge of the substrate 1. During operation, the heat on the effective conductor segment 21 is simultaneously dissipated by the insulating heat dissipation ribs 3 on both ends. With this configuration, both the inner and outer peripheral edges of the substrate 1 are fixedly connected to the motor housing, and the structural strength of the inner and outer peripheral edges of the substrate 1 is enhanced by the reinforcement of the motor housing. In addition, compared to the structure where the heat on the effective conductor segment 21 is discharged from one end by the insulating heat dissipation rib 3, the structure where the heat on the effective conductor segment 21 is discharged from one end by the insulating heat dissipation rib 3, has an insulating heat dissipation rib 3 on each end. When the heat on the effective conductor segment 21 is discharged from the insulating heat dissipation ribs 3 on both ends simultaneously, the heat conduction surface is larger, the heat discharge speed is faster and more timely, and the heat dissipation at both ends of the effective conductor segment 21 is more uniform. Moreover, the end of the insulating heat dissipation rib 3 extends to the mounting part 13 nearby, forming a shorter heat conduction path, a higher heat discharge speed, and a higher heat dissipation efficiency.

[0047] In this invention, an enhanced coreless stator preferably features a substrate 1 with a circular ring structure, effective conductor segments 21 in strip-shaped form, and insulating heat dissipation fins 3 in strip shape. All effective conductor segments 21 on the substrate 1 are distributed in a radiating pattern, and the length direction of the insulating heat dissipation fins 3 is aligned with the length direction of the effective conductor segments 21. To achieve uniform distribution, the effective conductor segments 21 are typically distributed in a radiating pattern. The alignment of the length direction of the insulating heat dissipation fins 3 with the length direction of the effective conductor segments 21 reduces the heat conduction path.

[0048] This invention relates to an enhanced coreless stator, wherein the single plate 10 is a polymer composite plate, such as a composite plate made of epoxy, glass fiber, etc. The polymer composite plate has high structural strength, making it suitable for high-power applications.

[0049] This invention relates to an enhanced coreless stator. The substrate 1 contains one, two, or even more single-plate 10s. When there are two or more single-plate 10s on the substrate 1, and a strip-shaped groove 11 is formed on the substrate 1, the same effective conductor segment 21 axially passes through all layers of single-plate 10s, achieving axial continuity. In this structure, on the one hand, the same effective conductor segment 21 strings together all layers of single-plate 10s, enhancing the strength of the connection structure of all layers of single-plate 10s; on the other hand, the uninterrupted arrangement of the effective conductor segment 21 along the axial direction of the substrate 1 provides the maximum dimension of the effective conductor segment 21 in that direction, enabling the effective conductor segment 21 to have a larger current cross-section and current density, achieving higher power output.

[0050] The present invention also provides a coreless disc motor, such as... Figure 6 As shown, the device includes the enhanced coreless stator 100, rotor 200, shaft 300, and motor housing 400 described in this invention. The shaft 300 is rotatably mounted on the motor housing 400. The enhanced coreless stator 100 and rotor 200 are located inside the motor housing 400. There are two rotors 200, which are located on opposite sides of the enhanced coreless stator 100. The rotor 200 is fixedly mounted on the shaft 300. The enhanced coreless stator 100 is rotatably mounted on the shaft 300. The mounting portion 13 of the enhanced coreless stator 100 is fixedly connected to the motor housing 400.

[0051] The present invention relates to a coreless disc motor. During operation, the rotating shaft 300 and the rotor 200 thereon rotate. The rotating rotor 200 and the enhanced coreless stator 100 work together to realize the motor function.

[0052] The present invention relates to a coreless disc motor. While retaining the advantages of traditional disc motors such as "thin thickness and compact structure", the enhanced coreless stator 100 has high strength and high power density, and also achieves high power output under ultra-thin plates, meeting the needs of high integration and high power application scenarios.

[0053] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent process transformations made using the content of the present invention specification, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. An enhanced coreless stator, comprising a substrate, the substrate comprising one or more stacked single plates, stator windings arranged on the substrate, the stator windings comprising effective conductor segments that cut axial magnetic flux, characterized in that: The effective conductor segment is sheet-shaped, and the main plane of the effective conductor segment is not parallel to the surface of the substrate.

2. The enhanced coreless stator according to claim 1, characterized in that: The principal plane of the effective conductor segment is perpendicular to the surface of the substrate.

3. The enhanced coreless stator according to claim 1, characterized in that: The angle α between the main plane of the effective conductor segment and the surface of the substrate satisfies the following relationship: 45° < α < 90°, and the projection portions of any two adjacent effective conductor segments on the substrate overlap.

4. The enhanced coreless stator according to claim 1, characterized in that: The substrate has a strip groove, which corresponds one-to-one with the effective conductor segment, and the effective conductor segment is fixed in the strip groove.

5. The enhanced coreless stator according to claim 4, characterized in that: The groove extends through the substrate in the vertical direction.

6. The enhanced coreless stator according to claim 4, characterized in that: The substrate is provided with an annular through hole on the same axis. The strip groove is located on the annular through hole. Each strip groove is divided into a first end and a second end by the annular through hole. The first end and the second end are respectively located on the substrate on both sides of the annular through hole.

7. The enhanced coreless stator according to claim 1, characterized in that: The substrate is provided with a mounting part that is connected and fixed to the motor housing. Several insulating heat dissipation ribs are installed on the surface of the substrate. One end of each insulating heat dissipation rib is connected to the effective conductor segment, and the other end extends to the mounting part of the substrate.

8. The enhanced coreless stator according to claim 7, characterized in that: The mounting portion is located at the outer peripheral edge of the substrate or the inner peripheral edge of the substrate.

9. The enhanced coreless stator according to claim 7, characterized in that: A reinforcing ring is coaxially mounted on the mounting portion of the substrate, and the end of the insulating heat dissipation rib extending to the mounting portion is connected to the reinforcing ring.

10. The enhanced coreless stator according to claim 7, characterized in that: The insulating heat dissipation ribs are distributed on both sides of the substrate.

11. The enhanced coreless stator according to claim 7, characterized in that: Each effective conductor segment has insulating heat dissipation ribs distributed on both ends, and each end of each effective conductor segment is connected to the corresponding insulating heat dissipation rib on its end side.

12. The enhanced coreless stator according to claim 7, characterized in that: Mounting portions are provided on both the outer and inner peripheral edges of the substrate. Each effective conductor segment has corresponding insulating heat dissipation ribs distributed on both ends. One end of each insulating heat dissipation rib is connected to the end of the effective conductor segment closest to it, and the other end extends to the mounting portion closest to it and is connected to the reinforcing ring.

13. The enhanced coreless stator according to claim 7, characterized in that: The substrate has a circular ring structure, the effective conductor segment is a strip-shaped sheet, and the insulating heat dissipation rib is strip-shaped; all the effective conductor segments on the substrate are distributed in a radiating pattern, and the length direction of the insulating heat dissipation rib is on the same straight line as the length direction of the effective conductor segment.

14. The enhanced coreless stator according to claim 1, characterized in that: The single board is a polymer composite board.

15. A coreless disc motor, characterized in that: The device includes an enhanced coreless stator, rotor, shaft, and motor housing as described in any one of claims 1 to 14. The shaft is rotatably mounted on the motor housing. The enhanced coreless stator and the rotor are located inside the motor housing. There are two rotors, each located on one side of the enhanced coreless stator. The rotors are fixedly mounted on the shaft. The enhanced coreless stator is rotatably mounted on the shaft. The enhanced coreless stator is fixedly connected to the motor housing.

Images