Disk Motor Coil Bonding and Cooling via Intermediate Patterns

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Solution Overview

Problem

The existing disk motor technology faces challenges with low inter-layer bonding strength due to large non-pattern-formed areas on coil disks, which affects bonding, and inadequate cooling solutions for high electric current applications, leading to heat generation issues.

Innovation Solution

The implementation of a disk motor design with reinforcing patterns between radial patterns on coil disks, enhancing bonding strength and incorporating extended radiating patterns for improved cooling, utilizing a sheet-shaped bonding layer and conductive materials for efficient heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the area of non-pattern-formed portion on coil disk surface is increased, then the radial dimension of the motor can be reduced, but the inter-layer bonding strength becomes low

Engineering Contradiction:

Improveradial dimensionVSAvoidinter-layer bonding strength

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The coil pattern is divided into multiple radial patterns or radial pattern groups extending from the center. Intermediate patterns are added between these radial patterns to serve dual purposes: maintaining electrical insulation while providing bonding surfaces. This segmentation allows the non-pattern-formed areas to be utilized effectively for bonding without compromising the motor's compact radial dimension.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The intermediate patterns formed between adjacent radial patterns serve multiple functions simultaneously: they act as electrical insulators between coil patterns while also providing bonding surfaces for laminating coil disks. This multi-functionality resolves the contradiction by making the non-pattern-formed areas productive for both insulation and bonding purposes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Power

If electric current of the disk motor is increased to obtain high output, then the power output is improved, but heat generation due to electric resistance becomes a problem

Engineering Contradiction:

Improvepower outputVSAvoidheat generation

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

The patent replaces traditional cooling mechanisms with a pattern-based thermal management system. The intermediate patterns and extended radiating patterns function as thermal conduction paths, substituting mechanical cooling systems with a passive thermal conduction approach integrated into the coil disk structure itself.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The cooling function is extended from the traditional two-dimensional coil pattern plane into the third dimension by adding intermediate patterns and extended radiating patterns that protrude or extend in the axial direction. This dimensional extension creates additional heat dissipation pathways without increasing the radial or planar footprint of the motor.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Strength

If dummy electrodes or surrounding patterns are provided outside the coil pattern to enhance bonding, then the inter-layer bonding strength is improved, but the radial dimension increases

Engineering Contradiction:

Improveinter-layer bonding strengthVSAvoidradial dimension

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

Instead of adding bonding patterns uniformly across the entire coil disk surface, the intermediate patterns are strategically placed only in the non-pattern-formed areas between adjacent radial patterns. This localized approach provides bonding functionality exactly where it is needed without extending the radial dimension of the motor.

Inventive Principle:

Principle #3Local quality

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 design significantly increases the bonding strength between coil disks and enhances cooling performance, addressing the limitations of existing technologies by providing a reliable and efficient disk motor with improved radiating capabilities.

Implementation Method 1

at least two coil disks which are bonded together

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

conductive materials for efficient heat transfer

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS9570952B2Disk motor, electric working machine including disk motor and method for manufacturing disk motor

Publication Date: 2017.02.14 KOKI HLDG CO LTD

AI summary

A disk motor including: a rotor; a stator; an output shaft concentrically fixed to the rotor; at least one coil disk which is provided to one of the rotor or the stator, a coil pattern which includes a plurality of radial patterns or radial pattern groups extending outwards in a radial direction from a center part of the coil disk being formed on at least one surface of the coil disk; an electric current supply portion which supplies electric current to the coil pattern; a magnetic flux generating portion which is provided to another of the rotor or the stator and faces the coil pattern; and an intermediate pattern which is formed between adjacent radial patterns or adjacent radial pattern groups on the coil disk.