Motor Casing Block for Heat Dissipation
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Solution Overview
Problem
High current passage through the coil in a motor leads to increased heat generation, causing a rise in coil temperature and resistance, which hinders the rotor's rotation speed and efficiency.
Innovation Solution
A motor design incorporating a casing with high thermal conductivity and a flexible casing block with high thermal conductivity materials to efficiently dissipate heat, along with a manufacturing method that integrates a stator core and terminals with an insulator to manage heat effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a large amount of current is passed through the coil to rotate the rotor at high speed, then the rotation speed is improved, but the heat generation increases causing the coil temperature to rise and resistance to increase
Solution Approach 1:
The patent converts the harmful heat generated by the coil into a beneficial effect by using it to heat and melt the resin material that bonds the terminal to the stator core. This eliminates the need for separate heating processes and ensures strong bonding while maintaining high rotation speed operation
Solution Approach 2:
The system uses its own operational heat (from current passage through the coil) to perform the bonding function, rather than requiring an external heating source. The heat generated during normal operation serves the dual purpose of both driving the motor and securing the terminal connection
2Temperature
If the coil is heated causing temperature rise, then heat dissipation becomes necessary, but adding heat dissipation structures increases device complexity
Solution Approach 1:
The casing block is designed to perform multiple functions simultaneously: it provides mechanical support for the terminal, electrically insulates the terminal from the stator core, and dissipates heat from the coil through its high thermal conductivity material. This integration of multiple functions into a single component reduces overall device complexity
Solution Approach 2:
The patent employs composite material strategy by using a casing block made of material with high thermal conductivity (such as metal) while incorporating insulating properties through design or coating, allowing simultaneous heat dissipation and electrical insulation without requiring separate components
3Reliability
If the terminal is insulated from the stator core, then electrical insulation is achieved, but heat dissipation path may be blocked
Solution Approach 1:
The casing block provides localized electrical insulation where needed (between terminal and stator core) while maintaining thermal conduction pathways through its material selection and structural design. Different regions of the casing block serve different functions: insulation at the contact interface and heat dissipation in the bulk material
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 design effectively dissipates heat generated in the coil, preventing resistance increases and allowing high-speed rotor operation with improved power utilization efficiency and dust-proofing.
Implementation Method 1
the casing includes a casing body with high thermal conductivity that includes an opening in which the terminal is disposed and houses the stator and a casing block disposed in the opening and with an insulating property and high thermal conductivity
Data Source
AI summary
A motor includes a stator including a terminal and a casing that houses the stator, in which the casing includes a casing body with high thermal conductivity that includes an opening in which the terminal is disposed and houses the stator and a casing block disposed in the opening and with an insulating property and high thermal conductivity, and the casing block includes a housing part that houses a distal end portion of the terminal.