Integrated Motor Frame with Diffuser Vanes
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Solution Overview
Problem
Electric motors used in various applications face challenges in reducing size, weight, and cost without compromising performance, particularly in handheld products where space and material efficiency are critical.
Innovation Solution
The design integrates a frame with an inner and outer wall that supports the rotor assembly and diffuser vanes, eliminating the need for separate components like rotor supports and diffusers, using a bearing assembly with a spring preload, and an aluminum impeller with a labyrinth seal, while the zinc frame absorbs noise and reduces turbulence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate components (rotor support, diffuser) are used, then structural integrity and function are ensured, but device complexity, size, and weight increase
Solution Approach 1:
The patent merges the rotor support function and diffuser function into a single integrated frame structure. The frame includes an inner wall that supports the rotor assembly and an outer wall that forms the diffuser, eliminating the need for separate rotor support components and separate diffuser components. This integration maintains structural integrity while reducing device complexity and component count.
Solution Approach 2:
The frame structure performs multiple functions simultaneously: it provides structural support for the rotor assembly through the inner wall, creates the diffuser channel for airflow through the annular space between inner and outer walls, and serves as the housing for the motor. This multi-functionality reduces the overall number of components needed in the motor assembly.
2Adaptability or versatility
If more components are used, then functional requirements are met, but size and weight increase
Solution Approach 1:
By combining the rotor support structure and diffuser into a single frame component, the patent eliminates the weight of separate rotor support brackets and separate diffuser housings. The integrated frame uses material more efficiently, reducing overall motor weight while maintaining all necessary functions.
Solution Approach 2:
The rotor assembly is nested within the bore of the inner wall, which is itself part of the integrated frame. This nested arrangement allows compact packaging of components without requiring additional structural elements, thereby minimizing motor weight while maintaining functional capability.
3Volume of moving object
If inner wall is shortened, then space for other components is created, but manufacturing complexity increases
Solution Approach 1:
The patent resolves the manufacturing complexity issue by using die-casting technology that can create the multi-dimensional frame structure with varying wall lengths in a single manufacturing operation. The inner wall is shorter axially than the outer wall, creating space for other components, but the complex geometry is achieved through mold design rather than multiple assembly steps, maintaining ease of manufacture.
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 minimizes the number of components, reduces size and weight, enhances balance and vibration reduction, and maintains performance by supporting the rotor assembly and reducing unwanted vibrations and noise.
Implementation Method 1
The bearing assembly may comprise a pair of bearings fixed to the shaft and a spring located between the two bearings. The spring can then act to apply a pre-load to the outer races of each of the bearings.
Implementation Method 2
The frame may be formed of zinc. Zinc has the advantage that it is acoustically dull, and so the frame is able to at least partly absorb noise generated by the motor during use.
Implementation Method 3
The inner wall may comprise an annular protrusion extending axially from one end of the inner wall, the annular protrusion being receivable within a recess in a hub of the impeller. This can create a labyrinth seal inside the hub of the impeller. This can prevent foreign objects from entering into the bearing assembly which could damage the rotor assembly
Data Source
AI summary
An electric motor including: a frame; a rotor assembly including a magnet, a bearing assembly, an impeller, and a shaft; and a stator assembly including a stator core and a bobbin. The frame has an inner wall and an outer wall, the outer wall surrounds the inner wall and defines an annular channel between the inner wall and the outer wall, and diffuser vanes extend from the inner wall to the outer wall through the annular channel. The inner wall defines a bore for supporting the rotor assembly, and the outer wall defines a substantially cylindrical outer casing of the motor.