Rotor Cover Segmentation and Mechanical Interlocking

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Solution Overview

Problem

The existing motor designs face issues with weld lines causing cracks in the cover and require adhesive application for assembling the rotor within protective cans, complicating the assembly process and limiting chemical resistance.

Innovation Solution

A rotor design featuring a rotor core with guide protrusions and a cover with alternating convex and concave portions, minimizing weld lines and eliminating the need for adhesive application by using a can member with groove portions that forcibly fit between magnets, ensuring secure assembly without adhesives.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a cover is used to fix the sensor magnet and rotor, then assembly is simplified, but weld lines occur during injection molding causing cracks

Engineering Contradiction:

Improveassembly simplicityVSAvoidcover integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The cover is divided into multiple sections with recesses that allow injection molding material to flow separately, preventing weld lines from forming continuous crack paths. The cover includes first, second, and third recesses that segment the molding process into distinct zones.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cover design incorporates varying thickness and recess locations tailored to specific areas where weld lines are most likely to occur. The recesses are strategically positioned to redirect material flow away from critical stress points while maintaining structural integrity in other regions.

Inventive Principle:

Principle #3Local quality

2Strength

If cans are used to protect magnets, then durability is improved, but adhesive application is required complicating the assembly process

Engineering Contradiction:

Improvemagnet protectionVSAvoidassembly process

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent replaces the chemical bonding method (adhesive) with a mechanical interlocking system. The can includes protrusions that fit into corresponding recesses on the rotor, creating a mechanical connection that eliminates the need for adhesive application while maintaining strong bonding.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The can and rotor are designed with complementary geometric features (protrusions and recesses) that automatically align and interlock during assembly. The mechanical structure itself provides the bonding function without requiring external adhesives or additional bonding processes.

Inventive Principle:

Principle #25Self-service

3Ease of manufacture

If molding type protection is used for magnets, then assembly is simplified, but chemical resistance is limited and crack risk increases

Engineering Contradiction:

Improveassembly simplicityVSAvoidchemical resistance

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent combines the molded protective structure with metallic can components that offer superior chemical resistance. The hybrid design integrates the manufacturing simplicity of molding with the chemical durability of metal, creating a protective system that leverages the advantages of both material types.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS11469641B2Rotor and motor comprising same

Publication Date: 2022.10.11 LG INNOTEK CO LTD

AI summary

The present invention provides a rotor comprising: a rotor core; a plurality of magnets disposed outside the rotor core; and a molding part disposed outside the plurality of magnets, wherein the rotor core includes a plurality of guide protrusions disposed between the plurality of magnets, and the distance from the center of the rotor core to the outer surface of the molding part passing across the center of one of the guide protrusions is shorter than the distance from the same to the outer surface of the molding part passing across the center of one of the plurality of magnets.