Multi-Component Rotor Hub Structure for Quiet, Secure Attachment

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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 detachment under rotational forces and noise generation due to inadequate material distribution and stress management.

Innovation Solution

A dual-ring rotor hub design featuring a central core and perimetrical ring with recesses that securely receive polymeric material, distributing stress and torque effectively through a combination of polymeric and metallic components, enhancing attachment strength and reducing noise.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If polymeric material is used in the rotor frame, then noise is reduced and vibration is dampened, but attachment strength to the central hub deteriorates under rotational forces

Engineering Contradiction:

Improvenoise and vibrationVSAvoidattachment strength

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The rotor frame combines polymeric material and metallic material in a composite structure. The polymeric material provides noise reduction and vibration dampening, while the metallic material embedded within or integrated with the polymeric material provides the necessary attachment strength to withstand rotational forces during motor operation.

Inventive Principle:

Principle #40Composite materials

2Stability of the object's composition

If polymeric material is distributed throughout the rotor frame, then stress is better managed and noise is reduced, but secure attachment to the central hub becomes difficult

Engineering Contradiction:

Improvestress distributionVSAvoidattachment reliability

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The rotor frame employs local quality by concentrating metallic material in specific regions where attachment to the central hub is required, while using polymeric material in regions where noise reduction and stress distribution are prioritized. This localized material placement allows the structure to simultaneously achieve good stress distribution and reliable attachment.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If a simple single-ring hub design is used, then manufacturing is simpler, but attachment strength and stress management are insufficient

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidattachment strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The central hub is segmented into multiple rings (inner ring and outer ring) rather than using a simple single-ring design. This segmentation allows for optimized stress distribution and enhanced attachment strength, with each ring serving specific functional requirements while remaining manufacturable through standard processes.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS11374448B2Multi-component rotor for an electric motor of an appliance

Publication Date: 2022.06.28 WHIRLPOOL CORP

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.