Multi-Component Rotor Hub Structure for Quiet Torque Transfer
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Solution Overview
Problem
Existing rotor designs for electric motors in laundry appliances face challenges in securely attaching polymeric materials to central hubs, leading to potential instability and noise generation under rotational forces.
Innovation Solution
A dual-ring rotor hub design featuring a central core and perimetrical ring with recesses that receive polymeric material to secure the rotor frame, utilizing a combination of polymeric and metallic materials to enhance strength and reduce noise, with the polymeric material injected into recesses to form a strong and quiet connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If polymeric material is used to attach the rotor frame to the central hub, then noise is reduced, but attachment strength and stability under rotational forces deteriorate
Solution Approach 1:
The patent employs a composite attachment structure combining polymeric material and metallic elements. The polymeric material provides noise reduction and vibration damping, while embedded metallic reinforcement elements (such as metal inserts or metal-coated regions) provide the necessary mechanical strength and stability to withstand rotational forces. This composite approach allows simultaneous achievement of quiet operation and secure attachment.
2Ease of manufacture
If a simple single-ring hub design is used, then manufacturing complexity is reduced, but attachment reliability and torque transfer capability deteriorate
Solution Approach 1:
The central hub is divided into multiple functional rings: an inner ring that interfaces with the drive shaft and an outer ring that interfaces with the rotor frame. This segmentation allows each ring to be optimized for its specific function while maintaining manufacturability through modular construction or sequential forming processes.
Solution Approach 2:
The design transitions from a single-plane attachment to a multi-dimensional structure with recesses that extend radially and axially. These three-dimensional recesses provide enhanced surface area and geometric interlocking between the hub and rotor frame, improving attachment reliability without significantly increasing manufacturing complexity.
3Strength
If recesses are added to the perimetrical ring to receive polymeric material, then attachment strength is improved, but device complexity increases
Solution Approach 1:
The recesses are integrated directly into the perimetrical ring structure during hub formation, combining the attachment feature with the existing hub geometry. This merging approach allows the recesses to be formed as part of the standard hub manufacturing process (such as injection molding or casting) without requiring separate components or assembly steps, thus improving attachment strength while minimizing added complexity.
Data Source
AI summary
A motor for a laundry appliance includes a drive shaft coupled to a drum at a first end. The rotor frame is coupled proximate the second end of the drive shaft, where the rotor frame includes at least one polymeric material. A central hub includes a core and a perimetrical ring that extends circumferentially around the core. A plurality of recesses are defined within a planar surface of the perimetrical ring, wherein a portion of the polymeric material is received within the plurality of recesses to secure the rotor frame to the central hub.