Stack-Type Stator Multi-Layer Substrate Slim Motor Design
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Solution Overview
Problem
Conventional blower motors for vehicle air purifiers face challenges such as high material loss, complex manufacturing processes, high equipment costs, and inefficiencies due to their core-type structure, which limits their slimness and efficiency.
Innovation Solution
A stack-type stator using a multi-layer substrate with patterned coil patterns and divided cores connected through holes, minimizing air gap occupation and reducing leakage magnetic flux, resulting in a slim, cost-effective, and efficient motor design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a core-type BLDC motor is used, then high magnetic flux density and torque are achieved, but material loss increases and manufacturing complexity increases
Solution Approach 1:
The stator core is divided into multiple stacked laminations instead of using a solid core structure. This segmentation reduces eddy current losses and allows for more efficient material utilization while maintaining the required magnetic flux density.
Solution Approach 2:
The motor design transitions from a conventional radial magnetic path to an axial flux configuration, changing the dimensional arrangement of magnetic components. This allows for reduced material loss while maintaining torque output through optimized magnetic circuit geometry.
2Power
If a core-type BLDC motor is used, then high torque is achieved, but device complexity and equipment cost increase
Solution Approach 1:
The stator is constructed from multiple identical stacked modules, each containing simplified core and winding structures. This modular segmentation reduces manufacturing complexity by allowing standardized production of individual stacks that are then assembled together to achieve the required torque.
Solution Approach 2:
Instead of manufacturing a complex single-piece stator, the design uses multiple copies of simpler stator stacks. Each stack is an identical copy that contributes to the total torque, simplifying the manufacturing process and reducing equipment requirements.
3Area of stationary object
If a double-rotor/single-stator type coreless BLDC motor is used, then installation space is optimized, but motor thickness increases
Solution Approach 1:
The motor adopts an axial flux configuration where the magnetic path is arranged in the axial direction rather than radially. This dimensional change allows for a compact footprint while reducing the overall thickness by eliminating the need for deep radial magnetic paths and complex rotor-stator arrangements.
Solution Approach 2:
The motor is divided into multiple thin stacked layers, each contributing to the magnetic circuit. This segmentation allows the motor to achieve the required magnetic flux with reduced individual layer thickness, resulting in a thinner overall motor while maintaining compact installation space.
4Area of stationary object
If a coreless type stator is used, then installation space is optimized, but motor efficiency decreases
Solution Approach 1:
The stator incorporates a segmented core structure with multiple laminated stacks rather than a coreless design. This segmentation provides defined magnetic paths that reduce leakage flux and improve motor efficiency while maintaining compact installation space through the modular stacked configuration.
Solution Approach 2:
By transitioning to an axial flux configuration with a structured core, the motor achieves efficient magnetic flux distribution in the axial direction. This dimensional change allows for optimized magnetic circuits that improve efficiency without compromising the compact installation footprint.
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
The solution enables a slim motor with improved productivity and reduced manufacturing costs, while enhancing motor efficiency by minimizing material loss and leakage magnetic flux, thus addressing the limitations of core-type motors.
Implementation Method 1
a plurality of coil patterns formed on the respective substrates of the multi-layer substrate and spirally patterned to surround the plurality of first through holes
Implementation Method 2
divided cores each having one side protruding above the plurality of coil patterns formed on the uppermost layer of the multi-layer substrate and the other side being coupled to one of the plurality of second through holes through one of the plurality of first through holes
Data Source
AI summary
Provided are a stack-type stator having coil patterns patterned on a multi-layer substrate, and a motor and a blower for an air purification system using the stator. A stack-type stator includes: a multi-layer substrate having first through holes; coil patterns formed on the respective substrates of the multi-layer substrate and spirally patterned to surround the first through holes and to form a plurality of turns; a stator yoke disposed at a lower portion of the multi-layer substrate and having second through holes at positions corresponding to the first through holes; and divided cores each having one side protruding above the coil patterns formed on the uppermost layer of the multi-layer substrate and the other side being coupled to one of the second through holes through one of the first through holes.