Motor Driver Resin Assembly for Flexible Cooling Placement
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Solution Overview
Problem
Brushless motors face insufficient heat dissipation and lack of positional flexibility for their drivers, which can lead to inadequate cooling and limited adjustability of the driver's position relative to the cooling air flow.
Innovation Solution
A driver configuration featuring an aluminum substrate with an insulating layer, electronic elements bonded to a copper foil layer, and a resin member that integrates a mold resin part, connector, and fitting part, allowing for efficient heat dissipation, electrical connection, and easy attachment/detachment from the motor, along with positional adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the driver is fixed at a default position on the motor, then the structure is simple and easy to manufacture, but the driver cannot be sufficiently cooled when cooling air does not hit it and positional adjustment is impossible
Solution Approach 1:
The driver is designed with a detachable mounting structure that allows it to be moved between different positions on the motor. The driver can be attached to various locations including the motor housing, stator, or rotor, enabling dynamic repositioning to optimize cooling efficiency based on cooling air flow patterns and thermal requirements.
2Reliability
If the driver is integrated permanently with the motor, then the structure is compact and reliable, but the driver cannot be removed or repositioned for cooling optimization
Solution Approach 1:
The driver assembly is segmented into separable components with standardized mounting interfaces. The driver can be detached from the motor and reattached to different positions, providing both operational flexibility and reliable reconnection through precision-machined mounting holes and electrical connectors.
3Ease of manufacture
If the driver position is fixed, then the manufacturing process is simple, but sufficient heat dissipation measures cannot be taken when cooling air flow is insufficient
Solution Approach 1:
The driver position can be changed to optimize heat dissipation by placing it in regions with better cooling air flow. The mounting structure allows repositioning the driver to areas where cooling air directly impinges, thereby changing the thermal environment without requiring complex cooling systems.
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 configuration ensures effective heat dissipation and allows for flexible positioning and easy installation/removal of the driver, enhancing cooling efficiency and operational reliability.
Implementation Method 1
heat generated by the electronic elements of the driver can be efficiently released to the outside through the aluminum substrate which forms one surface of the housing
Implementation Method 2
emissivity can be improved by the black surface of the aluminum substrate, and heat dissipation of the electronic elements can be further improved
Data Source
AI summary
A driver for motors according to the present invention is provided with: an aluminum substrate (10) which forms one surface of a housing; an insulating layer (11) which is formed on a surface of the aluminum substrate (10); a plurality of electronic elements (13) which are bonded onto a surface of the insulating layer (11), said surface being on a side opposite to the aluminum substrate (10); and a resin member (14) that covers the surface onto which the electronic elements (13) are bonded. This driver for motors is characterized in that the resin member (14) is obtained by integrating a mold resin part (20) which covers the electronic elements (13) from the upper surface side, a connector (21) which is electrically connected to the electronic elements (13), and a fitting part (22) which is used for fitting to a motor.