Ferrite Stator Assembly With PCB Coils for Faster Motor Switching
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Solution Overview
Problem
Conventional motor structures with silicon steel sheet stator assemblies suffer from slow rotational speed, high loss, and large size.
Innovation Solution
A motor structure utilizing a stator assembly with a ferrite core and coil circuit boards, where printed circuits are wound around magnetic conductive columns, replacing conventional coils, to enhance switching speed and reduce size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional coils wrapped around silicon steel sheet are used, then the motor structure is simple to manufacture, but the switching speed is slow and the size is large
Solution Approach 1:
The patent replaces the conventional mechanical coil winding structure with a printed circuit board (PCB) based coil structure. The PCB coils are fabricated using standard PCB manufacturing processes instead of manual or automated wire winding, thereby increasing switching speed while maintaining manufacturing simplicity through standardized production methods.
Solution Approach 2:
The patent changes the material parameters by using ferrite core instead of silicon steel sheet, and PCB material instead of copper wire. These parameter changes enable higher switching speeds and reduced size while maintaining the electromagnetic functionality of the motor.
2Volume of moving object
If ferrite core and printed circuits are used, then switching speed increases and size reduces, but manufacturing complexity increases
Solution Approach 1:
The patent replaces manual coil winding operations with automated PCB fabrication processes. The PCB coils are manufactured using standard industry processes such as copper deposition, etching, and lamination, which are highly automated and suitable for mass production, thereby reducing manufacturing complexity despite the advanced materials used.
3Power
If conventional silicon steel sheet stator is used, then the structure is robust, but power density is low and loss is high
Solution Approach 1:
The patent employs composite material construction by combining ferrite core with PCB coil structure. The ferrite material provides high magnetic permeability and low eddy current losses, while the PCB structure provides precise winding geometry and low resistance. This composite approach achieves high power density and low energy loss simultaneously.
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 achieves high power density and low inductance with a compact design by using ferrite core and printed circuits, improving switching speed and reducing the overall size.
Implementation Method 1
The at least one coil circuit board has a plurality of printed circuits corresponding to a quantity of the magnetic conductive columns, and the printed circuits are respectively wound around the magnetic conductive columns
Implementation Method 2
a material of the stator core being ferrite core or other magnetic material
Data Source
AI summary
A motor structure and a stator assembly thereof. The motor structure includes a housing, a stator assembly disposed in the housing, and a rotor assembly disposed in the housing. The stator assembly includes a stator core and at least one coil circuit board connected to the stator core. The stator core has a magnetic core body and a plurality of magnetic conductive columns that are disposed on the magnetic core body. A through hole is formed in a center of the magnetic core body, and the magnetic conductive columns are arranged around the through hole and are erected on the magnetic core body. The coil circuit board has a plurality of printed circuits corresponding to a quantity of the magnetic conductive columns, and the printed circuits are respectively wound around the magnetic conductive columns. The rotor assembly is configured to rotate through the stator assembly.