Overmolded Stator Fluid Pump Reducing Friction and Component Count
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Solution Overview
Problem
Existing motorized fluid pumps, such as vacuum pumps in automobiles, face challenges with high energy losses due to continuous operation and require numerous components, leading to increased assembly and production costs, as well as friction issues from metal rotors and aluminum flanges.
Innovation Solution
A motorized fluid pump design where the stator of the electric motor is overmolded with plastic to integrate guide cavities for both internal and external rotors, reducing the number of components and friction, and allowing for a more compact assembly with optional guide bearings for improved rotor guidance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal rotors and aluminum flanges are used with lubricant, then good sealing and compression efficiency are achieved, but friction forces increase and complexity increases
Solution Approach 1:
The patent merges the stator, guide flanges, and sealing elements into a single integrated plastic component through overmolding. The plastic material directly forms the guide cavities and sealing surfaces that previously required separate metal flanges and lubrication systems, eliminating multiple components while maintaining sealing and compression functions
Solution Approach 2:
The patent uses composite plastic material (overmolded stator) that combines structural support, sealing, and guiding functions in one material system. This replaces the metal-aluminum-lubricant composite system, reducing friction through the inherent low-friction properties of plastic while maintaining reliability
2Manufacturing precision
If multiple separate components (stator, external rotor, internal rotor, guide flanges) are used, then assembly and production costs increase, but manufacturing precision can be maintained
Solution Approach 1:
The patent combines multiple precision components (stator, guide flanges, sealing elements) into a single overmolded plastic part. This integration eliminates assembly operations and reduces production costs while the overmolding process itself provides precise dimensional control for the guide cavities and sealing surfaces
Solution Approach 2:
The plastic stator component performs multiple functions simultaneously: structural support, rotor guidance through integrated guide cavities, sealing through direct contact surfaces, and friction reduction. This multi-functionality eliminates the need for separate specialized components, reducing both cost and assembly complexity
Data Source
Figure 1~2
Figure 3~4b
Figure 5a~6
AI summary
The invention presents a motorized fluid pump (1) comprising a pump body (3), a pump internal rotor, an electric motor formed of a wound stator assembly (2) and an external rotor driven by the wound stator assembly (2), said pump internal rotor being able to rotate within the volume of the external rotor, said internal rotor being driven by the external rotor. The stator assembly (2) is overmoulded with a plastic material forming a first cavity for guiding the internal rotor and a first cavity for guiding the external rotor.