Conductive Aerodynamic Stator for Cooling and Power Routing
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Solution Overview
Problem
Air-moving devices face challenges in efficiently dissipating heat generated by control units and motors, leading to overheating, and require additional components and wiring for power and control signaling, which affect aerodynamic efficiency and increase weight and noise.
Innovation Solution
Integrating control units and motors within aero stator assemblies that are both thermally and electrically conductive, allowing heat dissipation through airflow and eliminating the need for struts and wiring by using conductive stator vanes for power and signaling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If control units and motors are integrated within aero stator assemblies, then heat dissipation is improved and weight is reduced, but the stator assembly becomes more complex
Solution Approach 1:
The patent combines multiple functions (heat dissipation, power transmission, control signaling, and structural support) into the stator assembly itself. The stator vanes are made thermally conductive to dissipate heat from integrated control units and motors, electrically conductive to provide power and control signals, and structurally integrated to eliminate separate mounting components like struts and wiring harnesses.
Solution Approach 2:
The stator assembly is designed to perform multiple functions simultaneously: it provides aerodynamic guidance through the vanes, acts as a heat sink for thermal management, serves as an electrical conductor for power and control signaling, and provides structural mounting for control units and motors. This multi-functionality reduces the need for separate dedicated components.
2Ease of operation
If additional components and wiring are added for power and control signaling, then control functionality is improved, but aerodynamic efficiency decreases and weight increases
Solution Approach 1:
The patent merges the functions of power transmission and control signaling with the aerodynamic stator structure. The stator vanes themselves serve as electrical conductors, eliminating the need for separate wiring harnesses and mounting struts that would disrupt airflow and reduce aerodynamic efficiency.
Solution Approach 2:
The patent replaces traditional mechanical wiring and mounting systems with an integrated conductive stator structure. Instead of using separate electrical wires and mechanical struts to connect control units and motors, the stator assembly itself provides both electrical conduction and structural support, reducing aerodynamic drag and improving efficiency.
3Ease of manufacture
If traditional wiring and struts are used for power and signaling, then installation is simplified, but weight increases and noise increases
Solution Approach 1:
The patent combines multiple components (wiring, struts, mounting brackets) into a single integrated stator assembly structure. The stator vanes serve simultaneously as aerodynamic surfaces, electrical conductors, and structural mounting elements, eliminating the need for separate wiring harnesses and mounting struts that add weight and noise.
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
This integration reduces overheating, weight, and noise while improving aerodynamic efficiency by dissipating heat and providing power/signaling through conductive stator vanes, eliminating the need for additional components and wiring.
Implementation Method 1
The aero stator assemblies in these examples are thermally conductive such that heat generated by the control unit, ESC, or motor is transferred away and dissipated
Implementation Method 2
The heat is transferred to thermally conductive stator vanes that are positioned within an airflow generated by an aerodynamic rotor of an air-moving device. The airflow across the thermally conductive stator vanes facilitate dissipation of the heat transferred from the control unit, ESC, or motor.
Implementation Method 3
An electrically conductive stator vane may conduct electric power to the control unit, ESC, or motor integrated into the aero stator assembly. An electrically conductive stator vane may conduct electric signaling to the control unit, ESC, or motor integrated into an aero stator assembly
Data Source
AI summary
An air-moving device may include an aerodynamic stator. The aerodynamic stator may be positioned forward of a motor of the air-moving device and aftward of an aerodynamic rotor of the air-moving device. A control unit may be integrated in and in thermal communication with the aerodynamic stator. The aerodynamic stator may transfer heat from the control unit to thermally conductive stator vanes of the aerodynamic stator. An airflow generated by the aerodynamic rotor may facilitate heat dissipation from the thermally conductive stator vanes. The aerodynamic stator may include electrically conductive stator vanes. The electrically conductive stator vanes may provide at least one of power or control signaling to the control unit.