(12) United States Patent
`(12) United States Patent
`Neal et al.
`Neal et ai.
`
`111111111111111111111111111111111111111111111111111111111111111111111111111
`US006892439Bl
`US00689.2439B1
`(10) Patent No.:
`US 6,892,439 B1
`US 6,892,439 BI
`(10) Patent No.:
`(45) Date of Patent:
`May 17, 2005
`(45) Date of Patent:
`May 17,2005
`
`(54) MOTOR WITH STATOR MADE FROM
`(54) MOTOR WITH STATOR MADE FROM
`LINEAR CORE PREFORM
`LINEAR CORE PREFORM
`(75) Inventors: Griffith D. Neal, Alameda, CA (US);
`(75)
`Inventors: Griffith D. Neal, Alameda, CA (US);
`Albert D. Neal, Long Beach, CA (US)
`Albert D. Neal, Long Beach, CA (US)
`
`(73) Assignee: Encap Motor Corporation, Alameda,
`(73) Assignee: Encap Motor Corporation, Alameda,
`CA(US)
`CA (US)
`
`FOREIGN PATENT DOCUMENTS
`FOREIGN PATENT DOCUMENTS
`870 878
`1/1979
`1/1979
`870878
`3/1982
`891258
`sº ; A1 ;
`2539492 A1
`3/1977
`0 747 943 A2 12/1996
`0747943 A2
`12/1996
`0 883 171 A1 12/1998
`0883 171 A1
`12/1998
`2 647 958
`12/1990
`2647958
`12/1990
`()5336722
`12/1993
`05336722
`12/1993
`10070870
`3/1998
`10070870
`3/1998
`410271719
`10/1998
`410271719
`10/1998
`11082508
`3/1999
`11082508
`3/1999
`1334.297
`8/1987
`1334297
`8/1987
`1494,148
`7/1989
`1494148
`7/1989
`WO 92/06532
`4/1992
`WO 92/06532
`4/1992
`WO 96/20501
`7/1996
`WO 96/20501
`7/1996
`WO 96/33533
`10/1996
`WO 96/33533
`10/1996
`WO 97/39870
`10/1997
`WO 97/39870
`10/1997
`OTHER PUBLICATIONS
`(51) Int. Cl." ................................................ H02K 15/16
`OTHER PUBLICATIONS
`(51)
`Int. CI? ................................................ H02K 15/16
`(52) U.S. CI. ............................................ 29/596; 310/43
`LNP Engineering Plastics, Advertisement entitled "Kon(cid:173)
`§ Hº search - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - jº LNP Engineering Plastics, Advertisement entitled “Kon
`(58) Field of Search .............................. 29/596; 310/43,
`duitTM Thermally COnductive Composites," undated (2
`- - - - - - - - - - - - - - - - - - - - - - - - - - - 31 0/179 21 6, 254
`duit" Thermally COnductive Composites,” undated (2
`310/179, 216, 254
`pages).
`2
`2
`pages).
`
`(*) Notice:
`( *) Notice:
`
`Subject to any disclaimer, the term of this
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`U.S.c. 154(b) by 0 days.
`
`(21) Appl. No.: 09/775,242
`(21) Appl. No.: 09/775,242
`:12, 21.
`(22) Filed:
`Feb. 1,2001
`(22) Filed:
`Feb. 1, 2001
`
`BE
`BE
`BE
`.
`DE
`EP
`EP
`EP
`EP
`FR
`FR
`JP
`JP
`JP
`JP
`JP
`JP
`JP
`JP
`SU
`SU
`SU
`SU
`WO
`WO
`WO
`WO
`WO
`WO
`WO
`WO
`
`(56)
`(56)
`
`References Cited
`References Cited
`U.S. PATENT DOCUMENTS
`U.S. PATENT DOCUMENTS
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`(Continued)
`(Continued)
`
`
`
`(Continued)
`(Continued)
`
`Primary Examiner—Joseph Waks
`Primary Examiner-Joseph Waks
`(74) Attorney, Agent, or Firm—Steven P. Shurtz, Brinks
`(74) Attorney, Agent, or Firm~teven P. Shurtz; Brinks
`Hofer Gilson & Lione
`Hofer Gilson & Lione
`(57)
`ABSTRACT
`ABSTRACT
`(57)
`A motor includes a stator having multiple conductors that
`A motor includes a stator having multiple conductors that
`create a plurality of magnetic fields when electrical current
`create a plurality of magnetic fields when electrical current
`is conducted through the conductors. The stator has a pair of
`is conducted through the conductors. The stator has a pair of
`opposing end surfaces in contact with each other forming a
`opposing end surfaces in contact with each other forming a
`toroidal core. A monolithic body of phase change material
`toroidal core. A monolithic body of phase change material
`substantially encapsulates the conductors and holds said
`substantially encapsulates the conductors and holds said
`toroidal core in place. The stator is formed by laminating
`toroidal core in place. The stator is formed by laminating
`strips together to form a linear core preform, winding wire
`strips together to form a linear core preform, winding wire
`around poles extending from a side of the core preform, then
`around poles extending from a side of the core preform, then
`rolling the preform to bring its two ends together to form the
`rolling the preform to bring its two ends together to form the
`toroidal core. Hard disc drives using the motor, and methods
`toroidal core. Hard disc drives using the motor, and methods
`of constructing the motor and hard disc drives are also
`of constructing the motor and hard disc drives are also
`disclosed.
`disclosed.
`
`26 Claims, 7 Drawing Sheets
`26 Claims, 7 Drawing Sheets
`
`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1008-0001
`
`

`

`US 6,892,439 BI
`US 6,892,439 B1
`Page 2
`Page 2
`
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`OTHER PUBLICATIONS
`OTHER PUBLICATIONS
`Product Information from Dupont Engineering Polymers
`Product Information from Dupont Engineering Polymers
`itled “Electrical/Electronic Thermoplastic Encapsula
`entitled "Electrical/Electronic Thermoplastic Encapsula(cid:173)
`entitle
`p
`p
`tion," undated, Publ. Reorder No.: H-58633 (R, 96.7), 20
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`pages.
`pages.
`.
`.
`-
`-
`LNP Engineering Plastics, Press Release entitled "LNP
`LNP Engineering Plastics, Press Release entitled “LNP
`Introduces First-Ever Line of Thermally Conductive Com(cid:173)
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`entitled "Epoxy Seal-Prevents Down Time and Keeps
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`-
`~~:
`-
`•.
`..
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`w.neeltran.thomasregister.com/olc/neeltran/neel9.htm>
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`Copy of Search Report for PCT Application No. USOO/
`- -
`-
`-
`19870 filed on Jul. 19, 2000 which is for a corresponding
`19870 filed on Jul. 19, 2000 which is for a corresponding
`PCT case filed by the assignee Encap Motors Corporation
`PCT case filed by the assignee Encap Motors Corporation
`who is also the assignee of this US application.
`who is also the assignee of this US application.
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`-
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`filed Mar. 2, 2001
`filed Mar. 2, 200l.
`• 2–2
`-
`* cited by examiner
`* cited by examiner
`
`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1008-0002
`
`

`

`u.s. Patent
`U.S. Patent
`
`May 17, 2005
`May 17, 2005
`
`Sheet 1 of 7
`Sheet 1 of 7
`
`US 6,892,439 BI
`US 6,892,439 B1
`
`
`
`K
`Q
`~
`Q
`S
`Q:
`Qs
`Y
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`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1008-0003
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`U.S. Patent
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`May 17, 2005
`May 17, 2005
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`Sheet 2 of 7
`Sheet 2 of 7
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`US 6,892,439 BI
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`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1008-0004
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`May 17, 2005
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`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1008-0005
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`U.S. patent
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`Sheet 4 of 7
`May 17, 2005
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`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1008-0006
`
`

`

`u.s. Patent
`U.S. Patent
`
`May 17, 2005
`May 17, 2005
`
`Sheet 5 of 7
`Sheet 5 of 7
`
`US 6,892,439 BI
`US 6,892,439 B1
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`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1008-0007
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`

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`u.s. Patent
`U.S. Patent
`
`May 17, 2005
`May 17,2005
`
`Sheet 6 of 7
`Sheet 6 of 7
`
`US 6,892,439 BI
`US 6,892,439 B1
`
`
`
`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1008-0008
`
`

`

`u.s. Patent
`U.S. Patent
`
`May 17, 2005
`
`Sheet 7 of 7
`
`US 6,892,439 B1
`US 6,892,439 BI
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`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1008-0009
`
`

`

`1
`1
`MOTOR WITH STATOR MADE FROM
`MOTOR WITH STATOR MADE FROM
`LINEAR CORE PREFORM
`LINEAR CORE PREFORM
`
`US 6,892,439 B1
`US 6,892,439 Bl
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`2
`2
`aligned along the radius, sometimes transverse to it, and
`aligned along the radius, sometimes transverse to it, and
`mostly at a varying angle to the radius. The un-aligned grain
`mostly at a varying angle to the radius. The un-aligned grain
`structure of conventional stators causes the magnetic flux
`structure of conventional stators causes the magnetic flux
`values to differ in parts of the stator and thus the motor does
`values to differ in parts of the stator and thus the motor does
`not have consistent and uniform torque properties as it
`not have consistent and uniform torque properties as it
`rotates.
`rotates.
`Another drawback with using circular steel pieces is that,
`Another drawback with using circular steel pieces is that,
`especially for inward facing poles, it has been difficult to
`especially for inward facing poles, it has been difficult to
`wind the wire windings tightly because of the cramped space
`wind the wire windings tightly because of the cramped space
`to work inside of the laminated stator body. The cramped
`10 to work inside of the laminated stator body. The cramped
`10
`working space creates a lower limit on the size of the stator
`working space creates a lower limit on the size of the stator
`and thus the motor. The limited working space also results
`and thus the motor. The limited working space also results
`in a low packing density of wire. The packing density of
`in a low packing density of wire. The packing density of
`wire coiled around the poles affects the amount of power
`wire coiled around the poles affects the amount of power
`generated by the motor. Increasing packing density increases
`15
`15 generated by the motor. Increasing packing density increases
`the power and thus the efficiency of the spindle motor.
`the power and thus the efficiency of the spindle motor.
`An important factor in motor design is to reduce stack up
`An important factor in motor design is to reduce stack up
`tolerances in the motor. Stack up tolerances reduce the
`tolerances in the motor. Stack up tolerances reduce the
`overall dimensional consistency between the components.
`overall dimensional consistency between the components.
`Stack up tolerances refer to the sum of the variation of all the
`Stack up tolerances refer to the sum of the variation of all the
`tolerances of all the parts, as well as the overall tolerance
`tolerances of all the parts, as well as the overall tolerance
`that relates to the alignment of the parts relative to one
`that relates to the alignment of the parts relative to one
`another. One source of stack up tolerances is from the
`another. One source of stack up tolerances is from the
`circular stator body. Generally, the thickness of rolled sheet
`circular stator body. Generally, the thickness of rolled sheet
`25
`steel is not uniform across the width of the sheet. Sometimes
`25 steel is not uniform across the width of the sheet. Sometimes
`the edges are thicker or thinner than the center. In a stator
`the edges are thicker or thinner than the center. In a stator
`made from circular stamped pieces, the thickness of indi
`made from circular stamped pieces, the thickness of indi(cid:173)
`vidual laminations are thus different from one side to the
`vidual laminations are thus different from one side to the
`other. When stacked together, this creates a stack up toler
`other. When stacked together, this creates a stack up toler(cid:173)
`ance problem. Furthermore, the circular stampings leave a
`ance problem. Furthermore, the circular stampings leave a
`lot of wasted steel that is removed and must be recycled or
`lot of wasted steel that is removed and must be recycled or
`discarded.
`discarded.
`Another important factor in motor design is the lowering
`Another important factor in motor design is the lowering
`of the operating temperature of the motor. Increased motor
`of the operating temperature of the motor. Increased motor
`temperature affects the electrical efficiency of the motor and
`temperature affects the electrical efficiency of the motor and
`bearing life. As temperature increases, resistive loses in wire
`bearing life. As temperature increases, resistive loses in wire
`increase, thereby reducing total motor power. Furthermore,
`increase, thereby reducing total motor power. Furthermore,
`the Arhennius equation predicts that the failure rate of an
`the Arhennius equation predicts that the failure rate of an
`electrical device is exponentially related to its operating
`electrical device is exponentially related to its operating
`temperature. The frictional heat generated by bearings
`temperature. The frictional heat generated by bearings
`increases with speed. Also, as bearings get hot they expand,
`increases with speed. Also, as bearings get hot they expand,
`and the bearing cages get stressed and may deflect, causing
`and the bearing cages get stressed and may deflect, causing
`non-uniform rotation reducing bearing life. This non
`non-uniform rotation reducing bearing life. This non-
`uniform rotation causes a further problem of limiting the
`45 uniform rotation causes a further problem of limiting the
`45
`ability of the servo system controlling the read/write heads
`ability of the servo system controlling the read/write heads
`to follow the data tracks on the magnetic media. One
`to follow the data tracks on the magnetic media. One
`drawback with existing motor designs is their limited effec
`drawback with existing motor designs is their limited effec(cid:173)
`tive dissipation of the heat, and difficulty in incorporating
`tive dissipation of the heat, and difficulty in incorporating
`heat sinks to aid in heat dissipation. In addition, in current
`50 heat sinks to aid in heat dissipation. In addition, in current
`50
`motors the operating temperatures generally increase as the
`motors the operating temperatures generally increase as the
`size of the motor is decreased.
`size of the motor is decreased.
`Manufacturers have established strict requirements on the
`Manufacturers have established strict requirements on the
`outgassing of materials that are used inside a hard disc drive.
`outgassing of materials that are used inside a hard disc drive.
`These requirements are intended to reduce the emission of
`55 These requirements are intended to reduce the emission of
`55
`materials onto the magnetic media or heads during the
`materials onto the magnetic media or heads during the
`operation of the drive. Of primary concern are glues used to
`operation of the drive. Of primary concern are glues used to
`attach components together, varnish used to insulate wire,
`attach components together, varnish used to insulate wire,
`and epoxy used to protect steel laminations from oxidation.
`and epoxy used to protect steel laminations from oxidation.
`In addition to such outgassed materials, airborne particu
`In addition to such outgassed materials, airborne particu-
`late in a drive may lead to head damage. Also, airborne
`late in a drive may lead to head damage. Also, airborne
`particulates in the disc drive could interfere with signal
`particulates in the disc drive could interfere with signal
`transfer between the read/write head and the media. To
`transfer between the read/write head and the media. To
`reduce the effects of potential airborne particulate, hard
`reduce the effects of potential airborne particulate, hard
`drives are manufactured to exacting clean room standards
`65 drives are manufactured to exacting clean room standards
`65
`and air filters are installed inside of the drive to reduce the
`and air filters are installed inside of the drive to reduce the
`contamination levels during operation.
`contamination levels during operation.
`
`FIELD OF THE INVENTION
`FIELD OF THE INVENTION
`The present invention relates generally to a motor. It
`The present invention relates generally to a motor. It
`relates particularly to a spindle motor such as used in a hard
`relates particularly to a spindle motor such as used in a hard
`disc drive, and to the construction of the stator for the motor.
`disc drive, and to the construction of the stator for the motor.
`
`BACKGROUND OF THE INVENTION
`BACKGROUND OF THE INVENTION
`Computers commonly use disc drives for memory storage
`Computers commonly use disc drives for memory storage
`purposes. Disc drives include a stack of one or more
`purposes. Disc drives include a stack of one or more
`magnetic discs that rotate and are accessed using a head or
`magnetic discs that rotate and are accessed using a head or
`read-write transducer. Typically, a high speed motor such as
`read-write transducer. Typically, a high speed motor such as
`a spindle motor is used to rotate the discs.
`a spindle motor is used to rotate the discs.
`In conventional spindle motors, stators have been made
`In conventional spindle motors, stators have been made
`by laminating together stamped pieces of steel. These
`by laminating together stamped pieces of steel. These
`stamped pieces of steel are generally circular in nature, but
`stamped pieces of steel are generally circular in nature, but
`also have “poles” extending either inwardly or outwardly,
`also have "poles" extending either inwardly or outwardly, 20
`20
`depending on whether the rotor is on the inside or surrounds
`depending on whether the rotor is on the inside or surrounds
`the stator. The stamped pieces are laminated together and
`the stator. The stamped pieces are laminated together and
`then coated with insulation. Wire is then wound around the
`then coated with insulation. Wire is then wound around the
`poles to form stator windings.
`poles to form stator windings.
`An example of a conventional spindle motor 1 is shown
`An example of a conventional spindle motor 1 is shown
`in FIG. 1. The motor 1 includes a base 2 which is usually
`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
`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
`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
`magnet 3 and flux return ring 5 are attached to the disc
`30
`support member 8. The stator 4 is separated from the base 2
`support member 8. The stator 4 is separated from the base 2 30
`using an insulator (not shown) and attached to 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
`using a glue. Distinct structures are formed in the base 2 and
`the disc support member 8 to accommodate the bearings 7.
`the disc support member 8 to accommodate the bearings 7.
`One end of the shaft 6 is inserted into the bearing 7
`One end of the shaft 6 is inserted into the bearing 7
`35
`positioned in the base 2 and the other end of the shaft 6 is
`positioned in the base 2 and the other end of the shaft 6 is 35
`placed in the bearing 7 located in the hub 8. A separate
`placed in the bearing 7 located in the hub 8. A separate
`electrical connector 9 may also be inserted into the base 2.
`electrical connector 9 may also be inserted into the base 2.
`Each of these parts must be fixed at predefined tolerances
`Each of these parts must be fixed at predefined tolerances
`with respect to one another. Accuracy in these tolerances can
`with respect to one another. Accuracy in these tolerances can 40
`40
`significantly enhance motor performance.
`significantly enhance motor performance.
`In operation, the disc stack is placed upon the hub. The
`In operation, the disc stack is placed upon the hub. The
`stator windings are selectively energized and interact with
`stator windings are selectively energized and interact with
`the permanent magnet to cause a defined rotation of the hub.
`the permanent magnet to cause a defined rotation of the hub.
`As hub 8 rotates, the head engages in reading or writing
`As hub 8 rotates, the head engages in reading or writing
`activities based upon instructions from the CPU in the
`activities based upon instructions from the CPU in the
`computer.
`computer.
`Manufacturers of disc drives are constantly seeking to
`Manufacturers of disc drives are constantly seeking to
`improve the speed with which data can be accessed. To an
`improve the speed with which data can be accessed. To an
`extent, this speed depends upon the efficiency of the spindle
`extent, this speed depends upon the efficiency of the spindle
`motor, as existing magneto-resistive head technology is
`motor, as existing magneto-resistive head technology is
`capable of accessing data at a rate greater than the speed
`capable of accessing data at a rate greater than the speed
`offered by the highest speed spindle motor currently in
`offered by the highest speed spindle motor currently in
`production. The efficiency of the spindle motor is dependent
`production. The efficiency of the spindle motor is dependent
`upon the dimensional consistency or tolerances between the
`upon the dimensional consistency or tolerances between the
`various components of the motor. Greater dimensional con
`various components of the motor. Greater dimensional con(cid:173)
`sistency between components leads to a smaller gap between
`sistency between components leads to a smaller gap between
`the stator 4 and the magnet 3, producing more force, which
`the stator 4 and the magnet 3, producing more force, which
`provides more torque and enables faster acceleration and
`provides more torque and enables faster acc