Motor, blower, air conditioner, and method of producing motor
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Solution Overview
Problem
The existing motor designs with heat sinks attached along the outer periphery of the casing face inefficiencies in heat radiation due to long distances from the stator or printed circuit board to the heat sink, leading to ineffective heat dissipation.
Innovation Solution
A motor design that integrates a heat radiation member with the stator assembly and printed circuit board using a resin, reducing the distance between the heat source and the heat sink, and utilizing a heat sink with fins and a thermally conductive resin to enhance heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the heat sink is attached along the outer periphery of the casing, then the heat sink can be positioned outside the motor, but the distance from the stator or printed circuit board to the heat sink becomes long and heat radiation efficiency deteriorates
Solution Approach 1:
The heat sink is integrated with the stator assembly into a unified structure, eliminating the need for separate attachment and reducing the thermal path length. The resin molding process combines the heat sink, stator, and printed circuit board into a single integrated assembly, enabling efficient heat transfer from the heat source to the heat sink.
Solution Approach 2:
A thermally conductive resin is introduced as an intermediary material between the stator/printed circuit board and the heat sink. This resin serves as a thermal conduit that efficiently transfers heat from the internal components to the heat sink, bridging the thermal gap that would otherwise exist in conventional attached designs.
2Loss of energy
If the heat sink is attached along the outer periphery of the casing, then the heat sink can be positioned outside the motor, but the heat of the motor cannot be efficiently radiated to the outside
Solution Approach 1:
The heat sink is merged with the stator assembly through resin integration, creating a unified thermal management system. This merging eliminates thermal interface resistance and reduces the distance heat must travel, thereby improving overall heat dissipation efficiency.
Solution Approach 2:
The patent employs a composite structure combining the heat sink material, stator components, and thermally conductive resin. This composite construction optimizes thermal pathways by selecting materials with appropriate thermal conductivity properties, enabling efficient heat transfer from the heat source through the resin to the heat sink.
3Device complexity
If the printed circuit board is integrated with the stator using resin, then the assembly is simplified, but the heat transfer path must be maintained
Solution Approach 1:
The resin material used for integration is specifically selected to possess high thermal conductivity, combining the functions of mechanical bonding and thermal conduction in a single material. This composite approach allows the resin to simultaneously integrate the printed circuit board with the stator while maintaining an efficient heat transfer path to the heat sink.
Solution Approach 2:
The resin serves multiple functions simultaneously: it acts as an adhesive to integrate the printed circuit board with the stator, provides structural support, and functions as a thermally conductive pathway to transfer heat to the heat sink. This multi-functionality simplifies the overall design while maintaining thermal performance.
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 improves heat radiation efficiency by reducing the distance between the heat source and the heat sink, effectively transmitting heat away from the motor components and preventing temperature rises, while also simplifying assembly and reducing costs.
Implementation Method 1
a heat radiation member to radiate heat of the stator assembly
Implementation Method 2
utilizing a heat sink with fins and a thermally conductive resin to enhance heat transfer
Data Source
AI summary
A motor includes a rotor, a stator assembly, a heat radiation member to radiate heat of the stator assembly, and a resin integrating the heat radiation member with the stator assembly.