Brushless Motor Stator Resin Structure for Propeller Cooling
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Solution Overview
Problem
The heat dissipation efficiency of conventional brushless motors used in drones is insufficient due to the stator and rotor being wholly covered by the case.
Innovation Solution
The motor design includes a stator fixed to a tubular member with a magnetic body, coil, and resin member, where the resin member enters between coil windings and forms side surfaces of the stator, opposing a blade in the axial direction to enhance heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the stator and rotor are wholly covered by the case, then the motor structure is compact and protected, but heat dissipation efficiency deteriorates
Solution Approach 1:
The resin member is divided into multiple functional parts: a first resin member entering between coil windings for direct heat absorption, a second resin member forming the stator side surface for heat transfer, and a third resin member opposing the blade for wind cooling. This segmentation allows each part to specialize in specific heat dissipation functions while maintaining overall structural integrity.
Solution Approach 2:
The resin member serves multiple functions simultaneously: it acts as an insulating material between coil windings, forms the structural side surface of the stator, and creates a heat dissipation surface opposing the propeller blade. This multi-functionality resolves the contradiction by integrating heat dissipation into existing structural components rather than adding separate cooling systems.
2Temperature
If the resin member enters between windings of the coil, then heat transfer from coil to resin member is enhanced, but manufacturing complexity increases
Solution Approach 1:
The resin member integrates multiple functions into a single component: electrical insulation between windings, structural support forming the stator side surface, and heat dissipation surface. This merging reduces the number of separate parts and assembly steps, thereby simplifying manufacturing despite the complex heat transfer requirements.
Solution Approach 2:
The resin member is configured to provide both electrical insulation properties (for coil winding separation) and thermal conduction properties (for heat dissipation). This composite functionality within a single material system achieves effective heat transfer from the coil to the external environment without requiring multiple separate components.
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 improves heat dissipation efficiency by allowing direct heat transfer from the coil to the resin member and subsequent dissipation, while also utilizing wind from the propeller for additional cooling.
Implementation Method 1
a part of the resin member enters into between windings of the coil, another part of the resin member forms a side surface of the stator, and another part of the resin member opposes the blade in an axial direction of the rotation shaft
Implementation Method 2
utilizing wind from the propeller for additional cooling
Data Source
AI summary
A motor of the present invention includes a rotation shaft, blades provided at the rotation shaft, a holder having tubular members, a rotor, and a stator opposing the rotor in a radial direction of the rotor. The stator is fixed to the tubular members, the stator includes a magnetic body, a coil and a resin member, a part of the resin member enters into between windings of the coil, another part of the resin member forms a side surface of the stator, and another part of the resin member opposes the blades in an axial direction of the rotation shaft.