Motor Stator Insulator with Axial Conductor Pin
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Solution Overview
Problem
High-speed motors in electronic devices generate excessive heat due to large electric currents, leading to reduced energy efficiency and potential reliability issues, as the copper wire coil temperature limits are exceeded, and bearing life is affected.
Innovation Solution
A motor design with an increased packing factor of the coil, achieved by winding the wire around teeth with a longer radial length and without obstacles, and using a stator core configuration with a second insulator projection and conductor pin to reduce heat generation and improve electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the motor rotates at high speed to increase heat dissipating capacity, then the cooling performance is improved, but the coil generates excessive heat due to large electric current
Solution Approach 1:
The patent changes the geometric parameters of the stator core, specifically increasing the radial length of the teeth and optimizing the yoke thickness. These parameter changes allow for increased coil packing factor without increasing the overall motor size, enabling higher power density while managing heat generation through improved magnetic path efficiency
Solution Approach 2:
The patent utilizes the radial dimension by extending the tooth length radially outward from the core back. This dimensional approach increases the available space for coil windings in the radial direction, allowing for higher packing factors and improved electromagnetic performance without increasing the axial or circumferential dimensions
2Quantity of substance
If the radial length of the tooth is increased to improve coil packing, then the coil packing factor is improved, but the magnetic path length increases causing flux leakage
Solution Approach 1:
The patent employs composite construction by combining the stator core with a yoke structure made of magnetic material. This composite approach provides a low-reluctance magnetic return path that compensates for the increased magnetic path length resulting from longer teeth, thereby reducing flux leakage and improving magnetic efficiency
Solution Approach 2:
The yoke acts as an intermediary magnetic path that connects the tips of the radially extended teeth. This intermediary structure provides a dedicated magnetic conduction path that reduces reluctance and prevents flux leakage, allowing the teeth to be extended radially for improved coil packing without suffering from increased magnetic path losses
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 design effectively decreases heat generation, enhances energy efficiency, and extends the motor's reliability and endurance by optimizing the coil's packing factor and magnetic path while maintaining high-speed operation.
Implementation Method 1
a conductor pin inserted into the hole of the projection. An axially one side end thereof is arranged in the hole and an axially other side end of the conductor pin protrudes into the axially other side from the projection
Implementation Method 2
A motor includes a stator unit and a rotor unit rotatable about a center axis and including a rotor magnet
Implementation Method 3
a coil formed by winding a wire around each of the teeth via the first insulator and the second insulator and is electrically connected to the conductor pin
Implementation Method 4
a first insulator arranged at an axially one side of the stator core and a second insulator arranged the other side of the stator core
Data Source
AI summary
Axially upper and lower end surfaces of the stator core 41 are substantially covered by the first insulator 421 and the second insulators 422, both of which are made of resin. A boss 4222 is arranged circumferentially between the two neighboring teeth 411. In the preferred embodiment of the present invention, three bosses 4222 are arranged at three out of four positions defined between any two neighboring teeth 411. A conductor pin 43 is inserted into each boss 4222 along the axial direction. The boss 4222 includes a hole extending axially upward from the axially lower end thereof, in which a conductor pin 43 is fitted. An axially lower position of the conductor pin 43 axially downwardly protrudes from the boss 4222. Into each of the notched portions 441 arranged to the circuit board 44, the conductor pin 43 is inserted and is soldered with the circuit board 44 such that the conductor pin 43 and the circuit board are electrically connected.