Vehicle Motor Rotor with Protruding Fixing Patterns

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Solution Overview

Problem

Existing motor rotor designs face issues with magnet instability and foreign material generation due to adhesive delamination at high temperatures, leading to noise, vibration, and increased costs.

Innovation Solution

A rotor design that fixes magnets without adhesives by using protruding fixing patterns on the rotor core members, which provide axial pressure to securely hold the magnets in place, eliminating the need for separate adhesives and enhancing structural stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If adhesive is used to fix magnets in the rotor core, then magnets can be initially fixed in position, but the adhesive delaminates at high temperatures causing magnet movement, foreign material generation, and fixed defects

Engineering Contradiction:

Improvemagnet fixation stabilityVSAvoidadhesive delamination at high temperature

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent removes the adhesive component from the magnet fixation system entirely. Instead of using adhesive to fix magnets, the invention uses a mechanical fixing pattern (protrusions) formed directly on the rotor core members that physically holds the magnets in place without any bonding agent, thereby eliminating the delamination problem associated with adhesives at high temperatures

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the chemical bonding mechanism (adhesive) with a mechanical fixing mechanism (protrusions on rotor core members). The fixing patterns with protrusions provide physical interlocking with the magnets, substituting the chemical adhesion method with a mechanical retention system that is thermally stable and does not degrade at high temperatures

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If high temperature resistant adhesive is applied to fix magnets, then magnet fixation stability at high temperature may improve, but application difficulty, cost, and process complexity increase

Engineering Contradiction:

Improvemagnet fixation stability at high temperatureVSAvoidadhesive application difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent eliminates the adhesive application process entirely by using a mechanical fixing pattern. The protrusions on the rotor core members are formed through stamping or molding processes that are already part of the rotor core manufacturing, removing the need for separate adhesive application steps and associated quality control issues

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The rotor core members themselves provide the fixing function through their own structure (protrusions formed as part of the rotor core). This self-fixing mechanism eliminates the need for external adhesive materials and application processes, making the manufacturing simpler and more cost-effective while maintaining high temperature reliability

Inventive Principle:

Principle #25Self-service

3Ease of operation

If magnets are fixed using only adhesive, then initial magnet positioning is achieved, but magnet movement and fixing defects occur during long-term operation and high temperature use

Engineering Contradiction:

Improvemagnet insertion simplicityVSAvoidmagnet position stability

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The patent segments the rotor core into multiple rotor core members, each with fixing patterns containing protrusions. This segmentation allows the magnets to be mechanically interlocked with individual rotor core members through the protrusions, providing stable positioning that prevents magnet movement during operation while maintaining ease of assembly

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent creates a composite structure where the rotor core members (with fixing patterns) and magnets form an integrated assembly. The protrusions on the rotor core members work together with the magnets to create a mechanically stable connection that maintains position stability during long-term operation and high temperature use

Inventive Principle:

Principle #40Composite materials

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 prevents magnet movement and delamination, reduces noise and vibration, and lowers production costs by ensuring a stable magnet fixation through non-adhesive coupling, maintaining reliability across varying environmental conditions.

Implementation Method 1

fixing patterns that protrude toward the center of the magnet insertion holes from one sides of the magnet insertion holes of the rotor core members respectively disposed at an uppermost layer and a lowermost layer

Methodology Applied

Scientific EffectAxial pressure: Mechanical Force

Data Source

PatentUS10432046B2Rotor, method of manufacturing the same, and motor including the rotor

Publication Date: 2019.10.01 LG INNOTEK CO LTD

AI summary

The present invention relates to a motor for a vehicle and a rotor applied thereto. Provided is a rotor including a rotor core in which a plurality of rotor core members are stacked and a plurality of magnets inserted into magnet insertion holes of the rotor core, and further including fixing patterns that protrude toward the center of the magnet insertion holes from one sides of the magnet insertion holes of the rotor core members respectively disposed at an uppermost layer and a lowermost layer.