Double Rotor BLDC Motor Stator with PCB Assembly
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Solution Overview
Problem
Conventional brush-type DC motors used in vehicle coolers for electric cars are inefficient, prone to wear, and not waterproof, leading to reduced performance and safety concerns, especially in adverse weather conditions, and require multiple motors to achieve high power, increasing complexity and power consumption.
Innovation Solution
A brushless direct-current (BLDC) motor with a double-rotor/single-stator structure and a stator designed for automatic assembly on a printed circuit board (PCB), where the whole surface is molded with insulation material, enhancing waterproofing and reducing weight and size, while maximizing thermosetting resin contact for improved durability and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a brush-type DC motor is used to achieve high power for cooling battery cars, then the cooling performance is improved, but the brush wear increases and reliability decreases
Solution Approach 1:
The patent replaces the mechanical brush-commutator system with a brushless DC motor structure. The commutation function is transferred to electronic control circuits, eliminating mechanical contact and brush wear while maintaining high power capability. This substitution resolves the contradiction between achieving high power and maintaining reliability.
2Power
If multiple DC motors are used to achieve high power, then the cooling performance is improved, but the structural complexity increases
Solution Approach 1:
The patent merges multiple motor functions into a single brushless DC motor unit with integrated electronic control. Instead of using multiple separate DC motors, the design consolidates the power generation and control functions into one integrated system, reducing structural complexity while maintaining the required power output for cooling applications.
3Ease of manufacture
If a conventional DC motor is used, then the manufacturing is simple, but the waterproof performance is insufficient for adverse weather conditions
Solution Approach 1:
The patent employs waterproof sealing structures including gaskets, seals, and protective coatings on the motor housing and electrical components. These flexible sealing elements prevent water and moisture ingress while maintaining the motor's operational integrity in adverse weather conditions, resolving the contradiction between manufacturing simplicity and waterproof performance.
4Power
If the motor size is increased to achieve high power, then the power output is improved, but the space occupation in the vehicle increases
Solution Approach 1:
The patent optimizes the motor's physical parameters including magnetic material properties, winding configurations, and structural dimensions to achieve higher power density. By changing these parameters, the motor delivers high power output in a compact form factor, reducing space occupation in the vehicle while maintaining the required cooling performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The BLDC motor achieves high power efficiency, reduced weight, and minimized space usage, ensuring reliable operation in various weather conditions and improving vehicle performance with a single motor, while ensuring worker safety and reducing electrical consumption.
Implementation Method 1
A brushless direct-current (BLDC) motor is employed to thereby attain high power, low weight and miniaturization
Data Source
AI summary
Provided are a stator for a brushless direct-current (BLDC) motor, a BLDC motor having a double-rotor/single-stator structure, and a vehicle cooler using the same, which uses a printed circuit board for an assembly that automatically sets an assembly position of stator core assemblies, to thereby secure waterproof, light-weight, and high power features. The stator includes a holder, a boss which has built-in bearings in order to support a rotational axis, and which enables the rotational axis to be rotated, a number of stator core assemblies which respectively enclose bobbins having inner and outer flanges at the inner and outer sides of a number of division type stator cores and in which coils are wound around the bobbins, and a printed circuit board for an assembly in which each stator core assembly is automatically position-set and then assembled and both end portions of the coil are mutually connected by each phase of U, V and W. After each stator core assembly has been temporarily assembled on the assembly PCB, the stator core assembly is insert molded using thermosetting resin to thereby integrally form the holder and the boss in the stator.