UNITED STATES DEPARTMENT OF COMMERCE
`United States Patent and Trademark Office
`
`October 29, 2016
`
`THIS IS TO CERTIFY THAT ANNEXED IS A TRUE COPY FROM THE
`RECORDS OF THIS OFFICE OF THE FILE WRAPPER AND CONTENTS
`OF:
`
`APPLICATION NUMBER: 111489,911
`FILING DATE: July 19,2006
`PATENT NUMBER: 7,928,348
`ISSUE DATE: Apri/19, 2011
`
`By Authority of the
`Under Secretary of Commerce for ntellectual Property
`and Director of the United State Pa ent and Trademark Office
`
`PAGE 1 OF 206
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`PETITIONERS' EXHIBIT 1102
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`U S P T O
`Document
`Re~uires PDF Reader
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`Date: 10124116
`Disc 1 of1
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`P a t e n t F i le W r a p p e r
`11489911
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`PAGE 2 OF 206
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`l
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`......
`~
`0
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`-::1 ~ rEf"Application of: Griffith D. Neal
`~ ~r~lectromagnetic Device With Integrated Fluid Flow Path
`m= en
`ttor-Bey Docket No: 8864/52
`~x~ss Mail" mailing label number: EV 316 048 809 US
`Date of Deposit: July 19 2006
`
`UTILITY PATENT APPLICATION TRANSMITTAL
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`Not a Small Entity
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`or
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`*If the difference in col. 1 is less than zero, enter "0" in col. 2.
`Fee payment:
`1Z1
`Credit card charge authorizations in the amount of $1 550 and $40 to cover the filing fees are enclosed.
`D
`Please charge my Deposit Account No. 23-1925 in the amount of$ __ . A copy of this Transmittal is
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`CORRESPONDENCE ADDRESS: please recognize the correspondence address for this application as the
`address associated with the following Customer Number:
`Customer No. 00757 - Brinks Hofer Gilson Liane
`PLEASE DIRECT all telephonic communications to:
`Steven P. Shurtz (tel: (312) 321-4200 ).
`
`BRINKS
`HOFER
`GILSON
`&L I 0 N E
`0
`~ ~
`Commissioner for Patents
`cnm
`P. 0. Box 1450
`~~
`Alexandria, VA 22313-1450
`.
`0~
`Transmitted herewith is a new application under 37 C.F.R. §1.53(b), including the following elements and other papers:~;::
`C')
`D Application Data Sheet. See 37 CFR § 1.76.
`1.
`Application including:
`~ ~
`1Z1 Title page
`1Z1 Specification, including claims and Abstract (11 pages)
`1Z1 Drawings M sheet(s))
`D Appendices:
`1Z1 Declaration (2. pages; 1Z1 Executed D Unexecuted)
`D Combined Declaration and Power of Attorney (_pages; D Executed D Unexecuted)
`D
`Information Disclosure Statement, including Form PT0-1449 (_sheets), and any required copies
`IZI
`Assignment Recordation Cover Sheet, with fee and attached assignment to: Encao Technologies Inc.
`1Z1
`Power of Attorney (1 pages; D by inventor 1Z1 by Assignee identified in item #3 above)
`D
`Nonpublication Request under 35 USC §122(b)(2)(B)(i)
`D
`Other:
`1Z1
`Return Postcard
`Fee calculation:
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`Applicant is a Small Entity.
`Claims as Filed
`Col. 1
`No. Filed
`
`Col.2
`No. Extra
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`For
`Basic Fee
`27-20
`Total Claims
`Independent Claims
`4-3
`Multiple Dependent Claims Present
`Utility Application Size Fee (for each additional 50 sheets
`that exceeds 100 sheets, including specification and drawings)
`Search Fee
`Examination Fee
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`7
`1
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`9.
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`July 19, 2006
`Date
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`Respectfully submitted,
`
`/Steven P. Shurtz/
`Steven P. Shurtz (Reg. No. 31,424)
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`PAGE 3 OF 206
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`"Express Mail" Mailing Label No. EV 316 048 809 US
`
`Date of Deposit : July(q. 2006
`
`Our Case No. 8864/52
`
`IN THE UNITED STATES PATENT AND TRADEMARK OFFICE
`APPLICATION FOR UNITED STATES LETTERS PATENT
`
`INVENTOR:
`
`GRIFFITH D. NEAL
`
`TITLE:
`
`ATTORNEYS:
`
`ELECTROMAGNETIC DEVICE WITH
`INTEGRATED FLUID FLOW PATH
`
`STEVEN P. SHURTZ
`Registration No. 31 ,424
`Customer No. 00757
`BRINKS HOFER GILSON & LIONE
`P.O. BOX 10395
`CHICAGO, ILLINOIS 60610
`(312) 321-4200
`
`PAGE 4 OF 206
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`1
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`ELECTROMAGNETIC DEVICE WITH INTEGRATED FLUID FLOW PATH
`
`FIELD OF THE INVENTION
`
`[0001]
`The present invention relates generally to electromagnetic devices
`that include heat exchange mechanisms. It relates particularly to motors,
`generators, transformers, relays and solenoids that are cooled by a fluid
`coolant. The devices can be used in various electronic products, such as a
`motor for hard disc drive or other consumer electronic device, a pump motor,
`a motor/generator used in a hybrid electric vehicle, a motor used in an air
`blower and a solenoid used in a fuel injector or liquid flow valve.
`
`BACKGROUND OF THE INVENTION
`
`[0002]
`The present invention utilizes aspects of Applicant's earlier
`inventions, some of which are repeated herein. U.S. Patents Nos. 6,362,554;
`6,753,682 and 6,911, 166, which are hereby incorporated by reference, further
`disclose some of these concepts.
`
`[0003]
`An example of a conventional motor 1 is shown in FIG. 1. The
`motor 1 includes a base 2 which is usually made from die cast aluminum, a
`stator 4, a shaft 6, bearings 7 and a disc support member 8, also referred to
`as a hub. A magnet 3 and flux return ring 5 are attached to the disc support
`member 8. The stator 4 is separated from the base 2 using an insulator (not
`shown) and attached to the base 2 using a glue. Distinct structures are
`formed in the base 2 and the disc support member 8 to accommodate the
`bearings 7. One end of the shaft 6 is inserted into the bearing 7 positioned in
`the base 2 and the other end of the shaft 6 is placed in the bearing 7 located
`in the hub 8. A separate electrical connector 9 may also be inserted into the
`base 2.
`[0004]
`Each of these parts must be fixed at predefined tolerances with
`respect to one another. Accuracy in these tolerances can significantly
`enhance motor performance.
`[0005]
`An important factor in motor design is the lowering of the
`operating temperature of the motor. Increased motor temperature affects the
`electrical efficiency of the motor and bearing life. As temperature increases,
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`resistive loses in wire increase, thereby reducing total motor power.
`Furthermore, the Arrhenius equation predicts that the failure rate of an
`electrical device is exponentially related to its operating temperature. The
`frictional' heat generated by bearings increases with speed. Also, as bearings
`get hot they expand, and the bearing cages get stressed and may deflect,
`causing non-uniform rotation and the resultant further heat increase. One
`drawback with existing motor designs is their limited effective dissipation of
`the heat, and difficulty in incorporating heat sinks to aid in heat dissipation. In
`addition, in current motors the operating temperatures generally increase as
`the size of the motor is decreased.
`[0006]
`Electromagnetic devices used in electrical products may need to
`be cooled to remove heat generated by operation of the device. It is well
`known that a fluid in the environment of the device can be used to aid cooling.
`As an example, a method of cooling a motor is to include a fan on the motor
`shaft. The fan then blows air past the motor. Air, however, has a fairly low
`heat capacity, and thus cannot carry away as much heat as is sometime
`generated by the motor. Also, in some applications there is no place to mount
`a fan. Other fluids, and liquids in particular, typically have a high enough heat
`capacity that they can be used to carry away heat. For example, a water
`pump driven by a motor uses the water to cool the pump. The problem with
`liquids, however, is getting them in contact with hot motor surfaces without
`damaging the motor, and then collecting them to carry them away. Thus, a
`need exists for an improved motor that includes an effective and practical way
`of using a liquid to carry heat away from the motor. Also, a need exits for
`improved methods of cooling other electromagnetic components.
`[0007]
`Also, there are times when the heat generated by operation of the
`electrical device, such as a motor, could be put to a beneficial use if there
`were a way to confine a fluid used in a heat transfer relationship with the
`device so that it could be directed to a point of desired use. Thus, if liquids or
`gasses could be channeled in such a way that they picked up heat from an
`electromagnetic device without damaging the device, and then carried that
`heat to a place where the heat was desired, that would be a great benefit.
`
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`[0008]
`One difficulty encountered in the design of electrical components
`is that various components need to withstand exposure to solvents and
`particulates. The environmental agents can corrode the conductors or
`inductors in the component. In pumps used for movement of corrosive
`agents, this can be a particular problem. In hybrid electric vehicles where the
`motor or generator resides inside of the transmission housing, stray metallic
`debris generated from the transmission gears may be thrown into the
`windings, damaging them to the point that the device no longer works.
`
`BRIEF SUMMARY OF THE INVENTION
`[0009]
`Electromagnetic devices have been invented which overcome
`many of the foregoing problems. In one class of devices, a heat transfer fluid
`flows through the device. In another class of devices, a heat transfer fluid is
`contained within the device. Encapsulating portions of the device at the same
`time a heat exchange mechanism is provided may provide the additional
`benefit of protecting the parts from corrosive or otherwise damaging
`environments.
`[0010]
`In a first aspect, the invention is an electromagnetic field-
`functioning device for heating a fluid comprising at least one electrical
`conductor that generates heat when in use; a monolithic body of injection
`molded thermoplastic material substantially encapsulating the at least one
`conductor; and a fluid pathway in the monolithic body, with at least one fluid
`inlet and at least one fluid outlet to the pathway to allow for passage of fluid
`through the pathway, the outlet directing the fluid to a place of usage wherein
`heat picked up by the fluid as it transfers through the device is put to
`functional use.
`[0011]
`In a second aspect, the invention is an electromagnetic field-
`functioning device for heating a fluid comprising at least one electrical
`conductor that generates heat when in use; a monolithic body of injection
`molded thermoplastic material substantially encapsulating the at least one
`conductor; and a fluid pathway in the monolithic body, with at least one fluid
`inlet and at least one fluid outlet to the pathway to allow for passage of fluid
`
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`through the pathway, the outlet directing the fluid to a place of usage wherein
`heat picked up by the fluid as it transfers through the device is put to
`functional use, and further wherein the monolithic body completely surrounds
`the device except for the inlet and the outlet.
`[0012]
`In a third aspect, the invention is an electromagnetic field(cid:173)
`functioning device for heating a fluid comprising at least one electrical
`conductor and at least one inductor that generates heat when in use; a
`monolithic body of injection molded thermoplastic material substantially
`encapsulating the at least one inductor; and a fluid pathway in the monolithic
`body, with at least one fluid inlet and at least one fluid outlet to the pathway to
`allow for passage of fluid through the pathway, the outlet directing the fluid to
`a place of usage wherein heat picked up by the fluid as it transfers through
`the device is put to functional use.
`[0013]
`In a fourth aspect, the invention is a fluid conveying mechanism
`comprising an electromagnetic field-functioning device having at least one
`electrical conductor; a monolithic body of injection molded thermoplastic
`material substantially encapsulating the at least one conductor; and a fluid
`pathway in the monolithic body, with at least one of a fluid inlet into the
`pathway and a fluid outlet from the pathway being formed in the body of
`. injection molded thermoplastic, and the pathway through the body being
`confined within the body.
`[0014]
`In another aspect, the invention is a fluid-cooled electromagnetic
`field-functioning device comprising one or more electrical conductors; a heat
`transfer fluid confinement member; and a monolithic body of phase change
`material substantially encapsulating both the one or more conductors and the
`heat transfer fluid confinement member.
`[0015]
`In yet another aspect the invention is a fluid-cooled
`electromagnetic device comprising an assembly comprising i) an inductor in
`operable proximity to at least one conductor that creates at least one
`magnetic field when electrical current is conducted by the conductor; and ii) a
`body of a phase change material substantially encapsulating the conductor;
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`and at least one liquid-tight coolant channel substantially encapsulated within
`the body of phase change material.
`[0016].
`In still another aspect the invention is a fluid-cooled
`electromagnetic field-functioning device comprising an inductor and at least
`one conductor that creates at least one magnetic field when electrical current
`is conducted by the conductor; a heat transfer fluid confinement member
`containing a heat transfer fluid; and a monolithic body of phase change
`material substantially encapsulating at least one of the inductor and the at
`least one conductor, the monolithic body being in thermal contact with the
`heat transfer fluid.
`[0017]
`A further aspect of the invention is a method of making a fluid-
`cooled electromagnetic field-functioning device comprising the steps of
`providing a core assembly comprising an inductor and at least one conductor
`that creates at least one magnetic field when electrical current is conducted
`by the conductor, substantially encapsulating at least one of the inductor and
`the at least one conductor in a body of phase change material; providing a
`heat transfer fluid confinement chamber in the body of phase change material;
`and, adding a heat transfer fluid to the confinement chamber ~nd sealing the
`chamber to retain the heat transfer fluid in the chamber.
`[0018]
`In another aspect the invention is a method of cooling an
`electromagnetic field-functioning device wherein the electromagnetic field(cid:173)
`functioning device comprises one or more electrical conductors and a
`monolithic body of phase change material substantially encapsulating the one
`or more conductors, wherein a heat transfer fluid flows through a confined
`path substantially within the body of phase change material to transfer heat
`away from the conductors.
`[0019]
`In one embodiment, a motor can be cooled by using a heat pipe
`embedded in a body of phase change material that also substantially
`encapsulates parts of the motor. In another embodiment, a motor can be
`cooled by passing liquid through a coolant channel encased in the body of
`phase change material also substantially encapsulating the motor component.
`The body of phase change material provides a path for the heat to be
`
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`transferred from the stator to the liquid coolant, where it can be carried away.
`The liquid is also confined, so that it does not contact other parts of the motor
`or get randomly discharged from the motor. Besides motors, other
`electromagnetic field function devices may be made with coolant channels.
`The flow path or chamber for the coolant may be formed by injecting gas into
`the molten thermoplastic after it has been injected into a mold but before it
`solidifies to form the body encapsulating the motor component, or component
`of other electromagnetic field-functioning devices. The foregoing and other
`features, and the advantages of the invention, will become further apparent
`from the following detailed description of the presently preferred
`embodiments, read in conjunction with the accompanying drawings. The
`detailed description and drawings are merely illustrative of the invention and
`do not limit the scope of the invention, which is defined by the app«;nded
`claims and equivalents thereof.
`
`BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
`[0020]
`FIG. 1 is an exploded, partial cross-sectional and perspective view
`of a prior art high speed motor.
`[0021]
`FIG. 2 is a perspective view of a stator used in a first embodiment
`of the present invention.
`FIG. 3 is an exploded, partial cross-sectional and perspective view
`[0022]
`of a high speed motor in accordance with a first embodiment of the present
`invention.
`[0023]
`FIG. 4 is a cross-sectional view of the high speed motor of FIG. 3.
`[0024]
`FIG. 5 is a schematic drawing of a mold used to make the
`encapsulated stator of the motor of FIG. 3.
`[0025]
`FIG. 6 is a schematic drawing of the mold of FIG. 5 in a dosed
`
`position.
`FIG. 7 is an exploded, partial cross-sectional and perspective view
`[0026]
`of a high speed motor in accordance with a second embodiment of the
`present invention.
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`[0027]
`FIG. 8 is a cross-sectional view of a high speed. motor in
`accordance with a third embodiment of the present invention.
`[0028]
`FIG. 9 is a cross-sectional view of a high speed motor in
`accordance with a fourth embodiment of the present invention.
`[0029]
`FIG. 10 is a perspective view of a stator, shaft and cold plate used
`in a fifth embodiment of the present invention.
`[0030]
`FIG. 11 is an exploded view of a hard disc drive of the present
`invention using the components of FIG 10.
`[0031]
`FIG. 12 is a perspective, partially cross-sectional view of a
`motor/generator for an electric vehicle using a liquid cooling channel.
`[0032]
`FIG. 13 is a cross sectional view of the motor/generator of
`FIG. 12.
`[0033]
`FIG. 14 is an exploded and partial cross sectional view of the
`motor/generator of FIG. 12.
`[0034]
`FIG. 15 is an enlarged cross-sectional view of a portion of the
`motor/generator of FIG. 12.
`[0035]
`FIG. 16 is a cross-sectional view of a motor in accordance with a
`seventh embodiment of the invention.
`[0036]
`FIG. 17 is a cross-sectional view of a transformer in accordance
`with the invention.
`[0037]
`FIG. 18 is a cross-sectional view of a solenoid used in a fuel
`injector in accordance with the invention.
`[0038]
`FIG. 19 is a cross-sectional view taken along line 19-19 of FIG.
`18.
`[0039]
`FIG. 20 is a cross-sectional view of a solenoid flow valve in
`accordance with the invention.
`[0040]
`FIG. 21 is a perspective view of a heat transfer fluid confinement
`member used in the valve of FIG 20.
`
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`DETAILED DESCRIPTION OF THE DRAWINGS AND
`PREFERRED EMBODIMENTS OF THE INVENTION
`
`[0041]
`The term "electromagnetic field-functioning device" as used in the
`present application includes electromagnetic devices that include one or more
`electrical conductors and use an electromagnetic field as part of the function
`of the device. In some embodiments, the device includes a moving part, and
`there is a relationship between movement of the moving part and flow of
`current in the conductors involving one or more magnetic fields. For example,
`in some devices, such as a motor or solenoid, current in the one or more
`conductors generates one or more magnetic fields, which generate a force
`that causes movement of the moving part. In other devices, such as a
`generator, the moving part generates a moving magnetic field, which in turn
`induces an electrical current in the one or more conductors. In some devices,
`like transformers, current conducted by the one or more conductors creates a
`magnetic field, and the magnetic field induces a current in a second conductor
`coupled to the magnetic field.
`[0042]
`The term "heat transfer fluid" as used in the present application
`includes both liquids and gases, as well as combinations thereof. While
`liquids typically have a higher heat capacity per unit volume, and will therefore
`be more frequently used in the present invention, gases, such as air, may also
`serve as heat transfer fluids.
`
`First Embodiment
`[0043]
`A first embodiment of a motor of the present invention is shown in
`FIGS. 2-4. The motor may be a "high speed" motor, meaning that the motor
`can operate at over 5,000 rpm. The motor 10 is designed for rotating a disc
`or stack of discs in a computer hard disc drive. Motor 10 is formed using an
`encapsulation method which reduces the number of parts needed to
`manufacture the motor as compared with conventional motors used for disc
`drives, thereby reducing stack up tolerances and manufacturing costs and
`producing other advantages discussed below.
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`(0044]
`Referring to FIG. 2, a stator 20 is first constructed, using
`conventional steel laminations 11 forming a magnetically inducible core 17
`having a plurality of poles 21 thereon, and wire windings 15 which serve as
`conductors. The conductors induce or otherwise create a plurality of
`magnetic fields in the core when electrical current is conducted through the
`conductors. In this embodiment, a magnetic field is induced in each of the
`poles 21.
`[0045]
`The stator 20 is then used to construct the rest of the motor 1 0
`(FIG. 3). The motor 10 includes a hub 12, which serves as a disc support
`member, the stator 20, a heat transfer fluid confinement member 62 and a
`body 14. Together the stator 20 and body 14 make up a stator assembly 13.
`The heat transfer fluid confinement member 62 constitutes a heat pipe in the
`embodiment of FIGS 2-4. The heat pipe has an annular shape. Heat pipes
`function by containing a fluid that carries heat from a high-temperature region
`to a low-temperature region, and then migrates back to the high-temperature
`region to repeat the cycle. Many heat pipes include a liquid that vaporizes at
`the temperature encountered in the high-temperature region, and travels as a
`gas to the low-temperature region, where it condenses. The heat pipes
`preferably include an internal capillary structure, such as a wick, saturated
`with the working fluid. As heat is input at the high-temperature region
`(sometimes referred to as the evaporator), fluid is vaporized, creating a
`pressure gradient in the heat pipe. This pressure gradient forces the vapor to
`flow along the pipe to the low-temperature region, where it condenses, giving
`up its latent heat of vaporization. The working fluid is then returned to the
`evaporator by the capillary forces developed in the wick structure. The heat
`. pipe is sealed to prevent loss of the heat transfer fluid. A heat pipe is thus
`one example of a heat transfer fluid confinement member comprising a heat
`transfer fluid in a sealed system. Heat pipes can be built in a variety of
`shapes. The internal structure of the heat pipe 62 is not shown, but may be of
`any known arrangement, optimized for the expected operating temperature of
`the motor.
`
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`10
`
`[0046]
`
`The body 14 is preferably a monolithic body 14. Monolithic is
`defined as being formed as a single piece. The body 14 substantially
`encapsulates the stator 20. Substantial encapsulation means that the body
`14 either entirely surrounds the stator 20, or surrounds significant areas of the
`stator that may be exposed. However, substantial encapsulation means that
`the body 14 and stator 20 are rigidly fixed together, and behave as a single
`component with respect to harmonic oscillation vibration.
`(0047]
`The body 14 is preferably formed of a phase change material,
`meaning a material that can be used in a liquid phase to envelope the stator,
`but which later changes to a solid phase. There are two types of phase
`change materials that will be most useful in practicing the invention:
`temperature activated and chemically activated. A temperature activated
`phase change material will become molten at a higher temperature, and then
`solidify at a lower temperature. However, in order to be practical, the phase
`change material must be molten at a temperature that is low enough that it
`can be used to encapsulate a stator. Preferred temperature activated phase
`change materials will be changed from a liquid to a solid at a temperature in
`the.range of about 200 to 700°F. The most preferred temperature activated
`phase change materials are thermoplastics. The preferred thermoplastic will
`become molten at a temperature at which it is injection-moldable, and then
`will be solid at normal operating temperatures for the motor. An example of a
`phase change material that changes phases due to a chemical reaction, and
`which could be used to form the body 14, is an epoxy. Other suitable phase
`change materials may be classified as thermosetting materials.
`[0048]
`As shown in FIG. 4, a shaft 16 is connected to the hub or disc
`support member 12 and is surrounded by bearings 18, which are adjacent
`against the body 14. A rotor or magnet 28 is fixed to the inside of the hub 12
`on a flange so as to be in operable proximity to the stator. The magnet 28 is
`preferably a permanent magnet, as described below. The body 14 includes a
`base 22. In addition, mounting features, such as apertures 25 (FIG. 3), and
`terminals comprising a connector 26 for connecting the conductors to an
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`11
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`external power source are formed as a part of the stator assembly. The
`terminals 26 are partially encapsulated in the body 14.
`[0049]
`The heat pipe 62 is positioned in the body 14 so that one end is
`near the stator 20, which will be the high-temperature region. The other end
`has one face that is not covered by the phase change material. This face is
`located just below the hub 12, so that air currents created by the spinning hub
`can convey heat away from the exposed face, which serves as the low(cid:173)
`temperature region. The heat pipe 62 is substantially encapsulated in the
`body 14, as the body 14 surrounds almost all of the heat pipe 62 except for
`the· minor exposed face, and the body 14 and heat pipe 62 are rigidly fixed
`together, and behave as a single component with respect to harmonic
`oscillation vibration.
`[0050]
`Referring to FIGS. 3-4, the base 22 of the body 14 is generally
`connected to the hard drive case (not shown). Connecting members (not
`shown), such as screws, may be used to fix the base 22 to the hard drive
`case, using holes 25 as shown in FIG. 3. Alternatively, other types of
`mounting features such as connecting pins or legs may be formed as part of
`the base 22. The connector 26 is preferably a through-hole pin type of
`connector 26 and is coupled through the hard drive case to the control circuit
`board residing on the outer surface of the base (not shown). Alternatively the
`connector may be a flexible circuit with copper pads allowing spring contact
`interconnection.
`[0051]
`The stator 20 is positioned in the body 14 generally in a direction
`perpendicular to an interior portion 30. Referring to FIG. 2, the stator 20 is
`preferably annular in shape and contains an open central portion 32. The
`poles 21 extend radially outward from this central portion 32. Faces of the
`poles 21 are positioned outward relative to the central portion 32 of the
`stator 20. The body 14 is molded around the stator 20 in a manner such that
`the faces of the poles are exposed and are surrounded by and aligned
`concentrically with respect to the disc support member 12. Alternatively, the
`poles may be totally encapsulated in body 14 and not be exposed.
`
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`12
`
`[0052]
`Referring to FIG. 4, the body 14 has an upper portion 40 that
`extends upwardly from the stator 20. The upper portion 40 is also preferably
`annular shaped. The body 14 includes the interior portion 30. The interior
`portion 30 is generally sized and shaped to accommodate the bearings 18.
`The interior portion 30 includes an upper support portion 42 and a lower
`support portion 44. In the embodiment illustrated in FIG. 4, the interior
`portion 30 is preferably cylindrically shaped.
`[0053]
`The phase change material used to make the body 14 is
`preferably a thermally conductive but non-electrically conductive plastic. In
`addition, the plastic preferably includes ceramic filler particles that enhance
`the thermal conductivity of the plastic so that it has a coefficient of thermal
`expansion similar to that of the heat pipe. In that way, as the encapsulated
`product changes temperature, either from cooling after been molded, or
`heating during operation, the body 14 will stay in close contact with the heat
`pipe, but will not expand faster and cause pressure on the heat pipe, or
`thermal hardening of the walls of the heat pipe. If the thermoplastic body and
`heat pipe were to separate, there would be a significant barrier to thermal
`conductivity across that juncture.
`[0054]
`A preferred form of plastic is polyphenyl sulfide (PPS) sold under
`the trade name "Konduit" by General Electric Plastics. Grade OTF-212-11
`PPS is particularly preferred. Examples of other suitable thermoplastic resins
`include, but are not limited to, thermoplastic resins such as 6,6-polyamide,
`6-polyamide, 4,6-polyamide, 2, 12-polyamide, 6, 12-polyamide, and
`polyamides containing aromatic monomers, polybutylene terephthalate,
`polyethylene terephthalate, polyethylene napththalate, polybutylene
`napththalate, aromatic polyesters, liquid crystal polymers, polycyclohexane
`dimethylol terephthalate, copolyetheresters, polyphenylene sulfide,
`polyacylics, polypropylene, polyethylene, polyacetals, polymethylpentene,
`polyetherimides, polycarbonate, polysulfone, polyethersulfone, polyphenylene
`oxide, polystyrene, styrene copolymer, mixtures and graft copolymers of
`styrene and rubber, and glass reinforced or impact modified versions of such
`resins. Blends of these resins such as polyphenylene oxide and polyamide
`
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`13
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`blends, and polycarbonate and polybutylene terephthalate, may also be used
`in this invention.
`[0055]
`Referring to FIG. 4, the bearings 18 include an upper bearing 46
`and a lower bearing 48. Also, each bearing 18 has an outer surface 50 and
`an inner surface 52. The outer surface 50 of the upper bearing contacts the.
`upper support portion 42 and the outer surface 50 of the lower bearing 48
`contacts the lower support portion 44. The inner surfaces 52 of the
`bearings 18 contact the shaft 16. The bearings are preferably annular
`shaped. The inner surfaces 52 of the bearings 18 may be press fit onto the
`shaft 16. A glue may also be used. The outer surface 50 of the bearings 18
`may be press fit into the interior portion 30 of the body 14. A glue may also
`be used. The bearings in the embodiment shown in FIGS. 3-4 are ball
`bearings. Alternatively other types of bearings, such as hydrodynamic or
`combinations of hydrodynamic and magnetic bearings, may be used. The
`bearings are typically made of stainless steel.
`[0056]
`The shaft 16 is concentrically disposed within the interior
`portion 30 of the body 14. The bearings 18 surround portions of the shaft 16.
`As described above, the inner surfaces 52 of the bearings are in contact with
`the shaft 16. The shaft 16 includes a top portion 54 and a bottom portion 56.
`The top portion 54 of the shaft 16 is fixed to the hub 12. The bottom
`portion 54 of the shaft 16 is free to rotate inside the lower bearing. Thus, in
`this embodiment, the shaft 16 is freely rotatable relative to the body 14. The
`shaft 16 is preferably cylindrical shaped. The shaft 16 may be made of
`stainless steel.
`[0057]
`Referring to FIG. 4, the hub 12 is concentrically disposed around
`the body 14. The hub 12 is fixed to the shaft 16 and is spaced apart from the
`body 14. The hub 12 includes a flux return ring 58 and the magnet 28. The
`flux return ring 58 is glued to the disc support member. The magnet 28 is
`glued to the hub 12. As shown in FIG. 4, the magnet 28 concentrically
`surrounds the portion of the body 14 that includes the stator 20. In this
`embodiment the magnet 28 and stator 20 are generally coplanar when the
`motor 10 is assembled.
`
`PAGE 17 OF 206
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`14
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`[0058]
`The magnet 28 is preferably a sintered part and is one solid piece.
`The magnet 28 is placed in a magnetizer which puts a plurality of discrete
`North and South poles onto the magnet 28, dependant on the number of
`poles 21 on the stator 20. The flux return ring 58 is preferably made of a
`magnetic steel. The hub is preferably made of aluminum. Also, the hub may
`be made of a magnetic m