`
`906L10lllllllllllllllllllllllllllll
`
`reCApplication of: Griffith D. Neal
`orb, Electromagnetic Device With Open, Non-Linear Heat Transfer System
`lllll
`ttogtey Docket No: 8864/50
`“Exfiess Mail" mailing label number: EV 316 048 809 US
`Date of Deposit: July 19 2006
`
`UTILITY PATENT APPLICATION TRANSMITTAL
`
`Commissioner for Patents
`P. O. Box 1450
`Alexandria, VA 22313-1450
`
`B R | N K s
`
`H 0 F E R .
`G | L S O N
`
`-m
`
`EDDIZIED
`
`El
`
`Applicant is a Small Entity.
`
`No. Extra
`For
`Basic Fee __
`It-
`[-
`
`Utility Application Size Fee (for each additional 50 sheets
`that exceeds 100 sheets, includin secification and drawins
`Search Fee
`
`Examination Fee
`
`'If the difference in col. 1 is less than zero, enter "0" in col. 2.
`Fee payment:
`E
`Credit card charge authorizations in the amount of $1000 and $40 to cover the filing fees are enclosed.
`.
`[I
`Please charge my Deposit Account No. 23—1925 in the amount of $
`. A copy of this Transmittal is
`enclosed.
`'
`
`:-
`
`The Director is hereby authorized to charge payment of the following fees associated with this
`E
`communication, or credit any overpayment, to Deposit Account No. 23-1925:
`E Any additional filing fees required under 37 CFR § 1.16.
`B Any patent application processing fees under 37 CFR §1.17.
`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 ALione
`
`PLEASE DIRECT all telephonic communications to:
`Steven P. Shurtz (tel: (312) 321-4200 ).
`
`July 19, 2006
`Date
`
`Respectfully submitted.
`
`[Steven P. Shurtz/
`
`Transmitted herewith is a new application under 37 C.F.R. §1.53(b), including the following elements and other papers: '
`1.
`Application including:
`I] Application Data Sheet. See 37 CFR § 1.76.
`E Title page
`E Specification, including claims and Abstract (fl pages)
`E Drawings (E sheet(s))
`El Appendices:
`E Declaration (g pages; E Executed E] Unexecuted)
`pages; E] Executed El Unexecuted)
`CI Combined Declaration and Power of Attorney (
`sheets), and any required copies
`Information Disclosure Statement, including Form PTO-1449 (
`Assignment Recordation Cover Sheet, with fee and attached assignment to: Encag Technologies Inc.
`Power of Attorney (1 pages; [:1 by inventor X by Assignee identified in item #3 above)
`Nonpublication Request under 35 USC §122(b)(2)(B)(i)
`Other:
`Return Postcard
`Fee calculation:
`
`Steven P. Shurtz (Reg. No. 31.424)
`
`m
`——
`-.-
`:-
`l-
`--
`l-
`l-
`- r
`l-
`
`r
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`+$200=
`
`$200 -
`$1000
`
`Petitioners' Exhibit 1005, pg. 1
`
`

`

`IN THE UNITED STATES PATENT AND TRADEMARK OFFICE
`APPLICATION FOR UNITED STATES LETTERS PATENT
`
`INVENTOR:
`
`GRIFFITH D. NEAL
`
`TITLE:
`
`ELECTROMAGNETIC DEVICE WITH OPEN,
`NON—LINEAR HEAT TRANSFER SYSTEM
`
`ATTORNEYS:
`
`STEVEN P. SHURTZ
`
`'
`
`“Express Mail" Mailing Label No. EV 316 048 809 US
`
`Date of Deposit : July]? 2006
`
`Our Case No. 8864/50
`
`(312) 321-4200
`
`Registration No. 31,424
`Customer No. 00757
`BRINKS HOFER GILSON & LIONE
`PO. BOX 10395
`CHICAGO, ILLINOIS 60610
`
`Petitioners' Exhibit 1005, pg. 2
`
`

`

`ELECTROMAGNETIC DEVICE WITH OPEN, NON—LINEAR HEAT
`TRANSFER SYSTEM
`
`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.
`
`operating temperature of the motor. Increased motor temperature effects the
`
`in the hub 8. A separate electrical connector 9 may also be inserted into the
`base 2.
`
`BACKGROUND OF THE INVENTION
`
`[0002]
`
`The present invention utilizes aspects of Applicant's earlier
`
`inventions, some of which are repeated herein. US. 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
`
`[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
`
`Petitioners' Exhibit 1005, pg. 3
`
`

`

`electrical efficiency of the motor and bearing life. As temperature increases,
`
`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.
`
`gasses could be channeled in such a way that they picked up heat from an
`
`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
`
`Petitioners' Exhibit 1005, pg. 4
`
`

`

`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.
`
`[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
`
`transfer fluid pathway in the monolithic body, with at least one fluid inlet and at
`
`benefit of protecting the parts from corrosive or otherwise damaging
`environments.
`
`[0010]
`
`In a first aspect, the invention is a fluid-cooled electromagnetic
`
`field-functioning device comprising at least one electrical conductor; a
`
`monolithic body of injection molded thermoplastic material substantially
`
`encapsulating the at least one conductor; and a non-linear heat transfer 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 heat transfer fluid through
`
`the pathway.
`
`[0011]
`
`In a second aspect, the invention is a fluid-cooled electromagnetic
`
`field-functioning device comprising at least one conductor and at least one
`
`inductor; a monolithic body of injection molded thermoplastic material
`
`substantially encapsulating the at least one inductor; and a non-linear heat
`
`Petitioners' Exhibit 1005, pg. 5
`
`

`

`4
`
`least one fluid outlet to the pathway to allow for passage of heat transfer fluid
`
`through the pathway.
`
`cooled electromagnetic field-functioning device comprising the steps of
`
`and at least one liquid-tight coolant channel substantially encapsulated within
`
`[0012]
`
`In a third aspect the invention is a fluid-cooled electromagnetic
`
`field-functioning device comprising at least one electrical conductor; a
`
`monolithic body of injection molded thermoplastic material substantially
`
`encapsulating the at least one conductor; and a non-linear heat transferfluid
`
`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 heat transfer fluid through
`
`the pathway, and wherein the monolithic body completely covers the exterior
`
`of the device except for fluid inlet and fluid outlet.
`
`[0013]
`
`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.
`
`[0014]
`
`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;
`
`the body of phase change material.
`
`[0015]
`
`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.
`
`[00.16]
`
`A further aspect of the invention is a method of making a fluid-
`
`Petitioners' Exhibit 1005, pg. 6
`
`

`

`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 and sealing the
`
`chamber to retain the heat transfer fluid in the chamber.
`
`[0017]
`
`In another aspect the invention is a method of cooling an
`
`electromagnetic field-functioning device wherein the electromagnetic field-
`
`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.
`[0018]
`In one embodiment, a motor can be cooled by using a heat pipe
`
`detailed description and drawings are merely illustrative of the invention and
`
`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
`
`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
`
`Petitioners' Exhibit 1005, pg. 7
`
`

`

`do not limit the scope of the invention, which is defined by the appended
`
`claims and equivalents thereof.
`
`BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
`
`[0019]
`
`FIG. 1 is an exploded, partial cross-sectional and perspective view
`
`of a prior art high speed motor.
`
`[0020]
`
`FIG. 2 is a perspective view of a stator used in a first embodiment
`
`of the present invention.
`
`[0021]
`
`FIG. 3 is an exploded, partial cross-sectional and perspective view
`
`‘ of a high speed motor in accordance with a first embodiment of the present
`invention.
`
`FIG. 12.
`
`[0022]
`
`[0023]
`
`FIG. 4 is a cross-sectional view of the high speed motor of FIG. 3.
`
`FIG. 5 is a schematic drawing of a mold used to make the
`
`encapsulated stator of the motor of FIG. 3.
`
`[0024]
`
`FIG. 6 is a schematic drawing of the mold of FIG. 5 in a closed
`
`position.
`
`[0025]
`
`FIG. 7 is an exploded, partial cross-sectional and perspective view
`
`of a high speed motor in accordance with a second embodiment of the
`
`present invention.
`
`[0026]
`
`FIG. 8 is a cross-sectional view of a high speed motor in
`
`accordance with a third embodiment of the present invention.
`
`[0027]
`
`FIG. 9 is a cross-sectional view of a high speed motor in
`
`accordance with a fourth embodiment of the present invention.
`
`[0028]
`
`FIG. 10 is a perspective view of a stator, shaft and cold plate used
`
`in a fifth embodiment of the present invention.
`
`[0029]
`
`FIG. 11 is an exploded view of a hard disc drive of the present
`
`invention using the components of FIG 10.
`
`[0030]
`
`FIG. 12 is a perspective, partially cross-sectional view of a
`
`motor/generator for an electric vehicle using a liquid cooling channel.
`
`[0031]
`
`FIG. 13 is a cross sectional view of the motor/generator of
`
`Petitioners' Exhibit 1005, pg. 8
`
`

`

`[0032]
`
`FIG. 14 is an exploded and partial cross sectional view of the
`
`motor/generator of FIG. 12.
`
`[0033]
`
`FIG. 15 is an enlarged cross-sectional view of a portion of the
`
`motor/generator of FIG. 12.
`
`[0034]
`
`FIG. 16 is a cross-sectional view of a motor in accordance with a
`
`seventh embodiment of the invention.
`
`[0035]
`
`FIG. 17 is a cross-sectional view of a transformer in accordance
`
`with the invention.
`
`[0036]
`
`FIG. 18 is a cross-sectional view of a solenoid used in a fuel
`
`injector in accordance with the invention.
`
`[0037]
`
`FIG. 19 is a cross-sectional view taken along line 19-19 of FIG.
`
`18.
`
`[0038]
`
`FIG. 20 is a cross-sectional view of a solenoid flow valve in
`
`accordance with the invention.
`
`[0039]
`
`' FIG. 21 is a perspective view of a heat transfer fluid confinement
`
`member used in the valve of FIG 20.
`
`like transformers, current conducted by the one or more conductors creates a
`
`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
`
`DETAILED DESCRIPTION OF THE DRAWINGS AND
`PREFERRED EMBODIMENTS OF THE INVENTION
`
`[0040]
`
`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
`
`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,
`
`Petitioners' Exhibit 1005, pg. 9
`
`

`

`8
`
`magnetic field, and the magnetic field induces a current in a second conductor
`
`coupled to the magnetic field.
`
`[0041]
`
`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
`
`First Embodiment
`
`be more frequently used in the present invention, gases, such as air, may also
`serve as heat transfer fluids.
`
`to a low-temperature region, and then migrates back to the high-temperature
`
`[0042]
`
`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.
`
`[0043]
`
`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.
`
`[0044]
`
`The stator 20 is then used to construct the rest of the motor 10
`
`(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
`
`Petitioners' Exhibit 1005, pg. 10
`
`

`

`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
`
`can be used to encapsulate a stator. Preferred temperature activated phase
`
`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.
`
`[0045]
`
`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.
`
`[0046]
`
`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
`
`Petitioners' Exhibit 1005, pg. 11
`
`

`

`10
`
`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.
`
`[0047]
`
`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
`
`external power source are formed as a part of the stator assembly. The
`
`mounting features such as connecting pins or legs may be formed as part of
`
`together, and behave as a single component with respect to harmonic
`oscillation vibration.
`
`terminals 26 are partially encapsulated in the body 14.
`
`[0048]
`
`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-
`
`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
`
`[0049]
`
`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
`
`Petitioners' Exhibit 1005, pg. 12
`
`

`

`11
`
`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
`
`conductivity across that juncture.
`
`connector may be a flexible circuit with copper pads allowing spring contact
`
`interconnection.
`
`[0050]
`
`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
`
`thefaces 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.
`
`[0051]
`
`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.
`
`[0052]
`
`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
`
`Petitioners' Exhibit 1005, pg. 13
`
`

`

`12
`
`[0053]
`
`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
`
`As described above, the inner surfaces 52 of the bearings are in contact with
`
`blends, and polycarbonate and polybutylene terephthalate, may also be used
`in this invention.
`
`[0054]
`
`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 bepress 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.
`
`[0055]
`
`The shaft 16 is concentrically disposed within the interior
`
`portion 30 of the body 14. The bearings 18 surround portions of the shaft 16.
`
`Petitioners' Exhibit 1005, pg. 14
`
`

`

`13
`
`the shaft 16. The shaft 16 includes atop 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.
`
`[0056]
`
`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.
`
`shaft 16. The bearings 18 facilitate the rotation of the shaft 16.
`
`[0057]
`
`The magnet 28 is preferably a sintered part and is one solid piece. I
`
`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 material to replace the flux return ring.
`
`[0058]
`
`As shown in FIGS. 3 and 4, the heat pipe may comprise just one
`
`circumferential loop. Of course multiple heat pipes or pipe loops could be
`
`provided in the body 14.
`
`Operation of the First Embodiment
`
`[0059]
`
`In operation, the motor shown in FIGS. 3-4 is driven by supplying
`
`electrical pulses to the connector 26. These pulses are used to selectively
`
`energize the windings 15 around the stator 20 poles 21. This results in a
`
`moving magnetic field. This magnetic field interacts with the magnetic field
`
`generated by the magnet 28 in a manner that causes the magnet 28 to rotate
`
`about the body 14. As a result, the hub 12 begins to rotate along with the
`
`Petitioners' Exhibit 1005, pg. 15
`
`

`

`14
`
`[0060]
`
`The coolant is captive to the system and continuously recirculates
`
`through the hollow structure of the heat pipe 62.
`
`Method of Making the First Embodiment
`
`[0061]
`
`The motor 10 shown in FIGS. 3 and 4 is made in part using an
`
`encapsulation technique. This encapsulation technique involves the following
`
`steps, and uses the mold shown in FIGS. 5 and 6. First, a mold is
`
`constructed to produce a part with desired geometry. The mold has two
`
`halves 72 and 74. Also, core pins 76 and 64 are connected to a plate 78 that
`
`is activated by hydraulic cylinders 77 within the mold tool. The stator 20 and
`
`heat pipe are placed within the mold and the two halves are closed. The core
`
`pins hold the heat pipe at a predetermined distance from the stator 20.
`
`Second, using solid state process controlled injection molding, plastic is
`
`injected through gate 80 around the stator 20 and heat pipe 62 so as to
`
`encapsulate the stator and form the body 14 shaped as shown in FIGS. 3 and
`
`4 with the heat pipe 62 inside of it. As plastic flows in, pins 76 are withdrawn
`
`so that the plastic completely surrounds the stator 20, and pins 64 are
`
`mold cavity, a runner, a stroke