PCB Stator Circulation Pump Merging Winding and Wall
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Solution Overview
Problem
Current circulation pumps for recirculating hot sanitary water and central heating systems rely on tubular stators with wire windings, which are complex, bulky, and costly to manufacture.
Innovation Solution
The use of a single-piece printed circuit board (PCB) as both the stator winding and a dividing wall to separate the dry and wet parts of the pump, significantly reducing the number of components and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a tubular stator with wire windings is used, then the pump can generate sufficient electromagnetic torque, but the device becomes bulky, complex, and expensive to manufacture
Solution Approach 1:
The patent merges the stator winding function with the dividing wall function into a single PCB component. The PCB serves dual purposes: it creates the electromagnetic field through printed circuit traces and simultaneously acts as the structural divider separating the wet and dry portions of the pump, eliminating the need for separate stator windings and dividing wall components
Solution Approach 2:
The PCB is designed to perform multiple functions simultaneously: it serves as the stator winding for electromagnetic torque generation, as the dividing wall for separation, and as the mounting substrate for electronic control components. This multi-functionality reduces overall device complexity and component count
2Reliability
If multiple separate components (stator, motor cup, bushing, division wall, electronic controller) are used, then each component can be optimized for its specific function, but the overall pump dimensions increase and manufacturing cost rises
Solution Approach 1:
The patent combines multiple separate components into integrated PCB structures. The stator winding, dividing wall, and electronic controller are merged into a single PCB assembly, significantly reducing the overall pump volume while maintaining the functional optimization of each component through careful PCB trace design and component placement
Solution Approach 2:
The electronic controller components are mounted directly on the PCB dividing wall, nesting the control electronics within the structural framework of the pump rather than requiring separate housing spaces. This nesting approach minimizes overall pump dimensions
3Reliability
If traditional wire windings and multiple components are used, then the pump can be robust and reliable, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent replaces traditional mechanical wire winding processes with PCB printing technology. The stator winding is created through standard PCB manufacturing processes (circuit trace deposition) rather than manual or automated wire winding, significantly simplifying manufacturing while maintaining electrical performance and reliability
Solution Approach 2:
The PCB serves as both the structural dividing wall and the electrical stator winding, eliminating the need for separate manufacturing processes for these components. This integration simplifies the supply chain and assembly processes while maintaining the reliability benefits of dedicated functional 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 solution results in a smaller, lighter, and less expensive circulation pump with reduced manufacturing costs and simplified production processes, while maintaining the required performance characteristics.
Implementation Method 1
The PCB printed circuit with integrated winding for the electromotor forms a spinning magnetic field, which in interaction with a permanent magnet rotor produces torque
Implementation Method 2
The other surface of the PCB dividing wall facing the hydraulic part is in contact with the seal, preferably circularly shaped, which ensures sealing and prevents water or moisture from entering the electric-electronic part
Data Source
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AI summary
The present invention belongs to the field of circulation pumps designed for forced flow of fluids in different hydraulic systems. The circulation pump comprises a wet, hydraulic part and a dry, electric-electronic part. The hydraulic part comprises a housing with two or more inlet-outlet openings for connection to a pipeline, wherein inside the housing a rotor, a rotor axis, a magnet, a seal and an impeller are provided. The electric-electronic part comprises a housing inside which control electronics are provide to control the pump or to control the drive based on user settings. Further, the electric-electronic part comprises a PCB dividing wall, which is designed as a printed circuit with integrated stator coil, and which at the same time functions as a wall to divide the hydraulic part of the electric-electronic part. The PCB dividing wall thus divides the hydraulic part and the electric-electronic part, wherein its surface with the circuit on the side of the electric-electronic part is protected against water or moisture, wherein the other surface of the PCB dividing wall facing the hydraulic part is in contact with the seal, preferably circularly shaped, which ensures sealing and prevents water or moisture from entering the electric-electronic part.