Miniature Drive Laminated Core Fixation via Carrier Sleeve
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Solution Overview
Problem
Existing miniature electric drives with laminated cores face complex and unreliable production processes, along with high eddy current losses due to flat electrical connections and imprecise fixation methods.
Innovation Solution
A method where annular disk-shaped laminations are held in a support sleeve with a force-fitting and form-fitting mechanism, using embossed rib-like longitudinal beads for radial and axial prestressing, eliminating adhesive bonding and minimizing eddy current losses through point contact with a thin, non-magnetic carrier sleeve.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If laminations are bonded with adhesive or painted layers, then the laminations are firmly connected, but the production process becomes complex and less reliable
Solution Approach 1:
The patent removes the adhesive bonding step entirely from the production process. Instead of applying paint or adhesive layers between laminations, the invention uses a support sleeve with mechanical retention features (longitudinal beads and holding embossments) to hold the laminations in place, thereby simplifying the production process while maintaining connection strength.
Solution Approach 2:
The patent replaces the chemical bonding mechanism (adhesive/paint) with a mechanical retention system. The support sleeve uses embossed longitudinal beads and holding embossments that mechanically interlock with the laminations through frictional and positive locking, eliminating the need for adhesive application and curing steps.
2Strength
If laminations are connected by axial weld seams, then material-to-material connection is achieved, but production reliability remains insufficient
Solution Approach 1:
The patent replaces welding (a thermal/mechanical joining process) with a purely mechanical retention system using the support sleeve. The longitudinal beads and holding embossments provide frictional and positive locking that secures laminations without requiring welding operations, thereby improving production reliability by eliminating weld seam defects.
3Manufacturing precision
If the laminated core is fixed with end plates in a support sleeve, then axial fixation is achieved, but the end plates may tilt causing imprecise fixation
Solution Approach 1:
The patent removes the end plates from the fixation system. Instead of using separate end plate components that can tilt, the invention integrates the retention function directly into the support sleeve through embossed longitudinal beads and holding embossments that provide stable, tilt-free fixation of the laminated core.
Solution Approach 2:
The patent transitions from a two-component system (laminated core + end plates) to a unified system where the support sleeve itself provides three-dimensional retention through its embossed features. The longitudinal beads provide radial positioning while holding embossments provide axial positioning, eliminating the dimensional instability caused by tilting end plates.
4Strength
If the laminated core has flat contact with the motor housing, then structural support is provided, but high eddy current losses occur
Solution Approach 1:
The patent segments the contact interface between the laminated core and support sleeve from continuous flat contact to discrete point contacts. The longitudinal beads create localized contact points that provide necessary structural support while minimizing the surface area for eddy current formation, thereby reducing energy losses.
Solution Approach 2:
The support sleeve acts as an intermediary between the laminated core and the motor housing. It provides structural support through its rigid construction while its thin sheet metal design and point contact geometry minimize eddy current losses, serving as a non-magnetic carrier that mechanically supports the magnetic components without significant magnetic flux penetration.
5Strength
If adhesive bonding is used for laminations, then connection is achieved, but production cost and time increase
Solution Approach 1:
The patent eliminates the adhesive bonding step from the production process. The support sleeve with its embossed longitudinal beads and holding embossments provides immediate mechanical retention of laminations upon assembly, eliminating the time-consuming adhesive application and curing steps while maintaining secure lamination connection.
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 approach simplifies and cost-effectively produces laminated cores with optimized magnetic properties by ensuring precise fixation and reducing eddy current losses, enhancing the reliability and efficiency of the miniature electric drive.
Implementation Method 1
The laminations are held in a non-positive and positive manner exclusively by friction and positive locking via embossing of the carrier sleeve formed radially inwards
Implementation Method 2
very high eddy current losses are likely to occur due to the flat electrical connection between the laminated core and the motor housing
Data Source
Figure 1~2
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Figure 11~12
AI summary
Sheet-metal plates (22) in the form of ring wheels for a cylindrical metal-sheet stack (20) are held axially and radially in a carrier sleeve surrounding the sheet-metal plates coaxially with a positive and/or non-positive fit and without adhesive or similar material. The sheet-metal plates maintain contact with the carrier sleeve via structural points distributed over a periphery. Independent claims are also included for the following: (1) A magnetic return-close element for a micro thruster; (2) A method for producing a return-close element for a micro-thruster.