BLDC Motor Stator Insulator for Heat Dissipation and Moisture Blocking
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Solution Overview
Problem
Conventional aircraft motors face issues with heat dissipation and moisture ingress, leading to electrical shorts and fires, particularly in BLDC motors used in drones and light aircraft, due to the stator generating excessive heat and being susceptible to foreign substances through cooling holes.
Innovation Solution
A stator with an insulating heat dissipation composite material is used to insulate spaces between the stator core and coil, combined with a water jacket for refrigerant circulation and air cooling through upper and lower covers, along with a rotor-outer stator structure for effective cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling holes are provided in the case to dissipate heat from the stator, then heat dissipation performance is improved, but foreign substances such as rainwater, moisture, or dust may enter the case causing electrical short circuits or fires
Solution Approach 1:
A waterproof cover is introduced as an intermediary component that blocks the cooling holes from the outside environment while allowing heat dissipation through alternative pathways or mechanisms, thus preventing foreign substance ingress while maintaining thermal management
Solution Approach 2:
The harmful function of the cooling holes (allowing foreign substance entry) is separated from their useful function (heat dissipation). The waterproof cover extracts the protective function, allowing the cooling holes to focus solely on thermal management without compromising electrical safety
2Object-affected harmful factors
If a tarp such as vinyl is used to cover the electric motor to prevent foreign substance ingress, then protection against moisture and dust is improved, but the solution becomes temporary and cumbersome
Solution Approach 1:
The protective function previously provided by external tarps is merged into the motor housing structure itself through the waterproof cover. This integration eliminates the need for separate protective components, reducing overall system complexity while maintaining effective protection against foreign substances
3Temperature
If an insulating heat dissipation composite material is used to form the stator support, then both heat dissipation performance and insulation performance are improved, but the material selection and manufacturing process become more complex
Solution Approach 1:
An insulating heat dissipation composite material is used for the stator support, combining materials with complementary properties (insulating and heat-dissipating characteristics) into a single integrated component that simultaneously addresses both electrical isolation and thermal management requirements
Solution Approach 2:
The stator support structure is designed to perform multiple functions simultaneously: providing mechanical support, electrical insulation, and heat dissipation. This multi-functionality reduces the need for separate components and simplifies the overall assembly process despite the complexity of the composite material itself
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 solution provides enhanced heat dissipation, insulation, and moisture resistance, preventing electrical shorts and fires while maintaining mechanical strength, improving motor efficiency and lifespan.
Implementation Method 1
an insulator formed to surround an outer circumferential surface on which a coil is wound in each of the plurality of teeth; and a stator coil wound around an outer circumferential surface of the insulator
Implementation Method 2
a water jacket for refrigerant circulation
Implementation Method 3
air cooling through a radial gap type BLDC motor design, which includes a rotor with bridges and through holes for enhanced cooling
Data Source
AI summary
Provided are a stator, and a propeller driving device and an aircraft using the stator. The propeller driving device includes: a radial gap type BLDC motor with an inner rotor-outer stator structure where a rotor is placed in a circumferential shape with an air gap inside a stator; and a propeller installation bracket for mounting a propeller to a rotary shaft of the motor, wherein the stator includes: a stator core including an annular back yoke having a predetermined width to form a magnetic circuit and teeth extending from the back yoke in a central direction; an insulator formed to surround an outer circumferential surface on which a coil is wound in each tooth; and a stator coil wound around an outer circumferential surface of the insulator in each tooth. The insulator is formed of an insulating heat dissipation composite material having both heat dissipation performance and insulation performance.