Disk Motor Insulating Resin Layer Thermal Management
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Solution Overview
Problem
The high cost and limited availability of dysprosium, used in neodymium magnets, lead to thermal demagnetization issues in disk motors, particularly due to heat transfer from the rotor to the magnet, which affects the heat resistance performance of low-cost neodymium magnets with reduced dysprosium content.
Innovation Solution
Incorporating an insulating resin layer between the coil pattern and the magnet, as well as between the coil disk and the stator, to reduce heat transfer and prevent thermal demagnetization, while using a metal case to hold the magnet and cover the commutator and coil disks, thereby enhancing heat insulation and reducing the risk of thermal demagnetization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dysprosium is mixed to neodymium magnet to improve heat resistance, then thermal demagnetization is reduced, but material cost increases and availability decreases
Solution Approach 1:
An insulating resin layer is introduced as an intermediary between the coil pattern and the magnet. This resin layer acts as a thermal barrier that interrupts heat transfer from the coil to the magnet, thereby protecting the magnet from thermal demagnetization without requiring additional dysprosium content.
2Quantity of substance
If low-cost neodymium magnet with reduced dysprosium content is used, then material cost decreases, but heat resistance performance deteriorates
Solution Approach 1:
The insulating resin layer serves as a protective intermediary that compensates for the reduced heat resistance of low-dysprosium magnets by blocking thermal pathways from the coil to the magnet, enabling the use of cost-effective magnet materials without sacrificing thermal stability.
3Reliability
If heat transfer from rotor to magnet is not suppressed, then thermal demagnetization occurs, but adding insulation increases device complexity
Solution Approach 1:
A thin insulating resin film or layer is applied between the coil pattern and the magnet. This thin-film approach provides effective thermal isolation while adding minimal structural complexity, maintaining the compactness and simplicity of the motor design.
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 insulating resin layer effectively reduces heat transfer to the magnet, preventing thermal demagnetization and allowing the use of low-cost neodymium magnets with reduced dysprosium content, thereby improving heat resistance and reducing material costs while maintaining motor performance.
Implementation Method 1
an insulating resin layer is provided between the coil pattern and the magnet
Data Source
AI summary
A disk motor including: a rotor; a stator; at least one coil disk provided to one of the rotor and the stator; at least one magnet provided to the other of the rotor and the stator and facing a coil pattern of the coil disk; a current supply part for supplying current to the coil pattern; and an output shaft rotated by a rotating force of the rotor, wherein an insulating resin layer is provided between the coil pattern and the magnet.