(12) United States Patent
`(12) United States Patent
`Neal
`Neal
`
`111111111111111111111111111111111111111111111111111111111111111111111111111
`US006362554Bl
`US006362554B1
`(10) Patent No.:
`US 6,362,554 B1
`US 6,362,554 BI
`(10) Patent No.:
`Mar. 26,2002
`(45) Date of Patent:
`(45) Date of Patent:
`Mar. 26, 2002
`
`(54) STATOR ASSEMBLY
`(54) STATOR ASSEMBLY
`
`(75) Inventor: Griffith D. Neal, Alameda, CA (US)
`(75)
`Inventor: Griffith D. Neal, Alameda, CA (US)
`
`(73) Assignee: Encap Motor Corporation, Alameda,
`(73) Assignee: Encap Motor Corporation, Alameda,
`CA (US)
`CA(US)
`
`(*) 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.: 09/470,429
`(21) Appl. No.: 09/470,429
`-
`(22) Filed:
`Dec. 22, 1999
`(22) Filed:
`Dec. 22, 1999
`- -
`-
`Related U.S. Application Data
`Related U.S. Application Data
`(60) Provisional application No. 60/146,446, filed on Jul. 29,
`(60) rºom application No. 60/146,446, filed on Jul. 29,
`1999.
`-
`Int. CI? .................................................. H02K 1/12
`(51)
`(51) Int. Cl." .................................................. H02K 1/12
`(52) U.S. Cl. ........................... 310/254; 310/43; 29/596;
`(52) U.S. CI. ........................... 310/254; 310/43; 29/596;
`264/272.2
`e
`264/272.2
`(58) Field of Search .............................. 310/43, 51, 89,
`(58) Field of Search .............................. 310/43, 51, 89,
`310/254; 29/596, 606; 264/272.13, 272.2
`310/254; 29/596, 606; 264/272.13, 272.2
`
`(56)
`(56)
`
`BE
`BE
`
`References Cited
`References Cited
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`U.S. PATENT DOCUMENTS
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`FOREIGN PATENT DOCUMENTS
`FOREIGN PATENT DOCUMENTS
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`1/1979
`870.878
`1/1979
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`
`
`BE
`BE
`DE
`DE
`EP
`EP
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`EP
`
`3/1982
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`3/1977
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`12/1998
`0883 171 A1
`-
`-
`(List continued on next page.)
`(List continued on next page.)
`OTHER PUBLICATIONS
`OTHER PUBLICATIONS
`
`U.S. application No. 09/470,428, filed Dec. 22, 1999, copy
`U.S. application No. 09/470,428, filed Dec. 22, 1999, copy
`of claims enclosed.
`of claims enclosed.
`U.S. application No. 09/470,432, filed Dec. 22, 1999, copy
`U.S. application No. 09/470,432, filed Dec. 22, 1999, copy
`of claims enclosed.
`of claims enclosed.
`U.S. application No. 09/470,430, filed Dec. 22, 1999, copy
`U.S. application No. 09/470,430, filed Dec. 22, 1999, copy
`of claims enclosed.
`of claims enclosed.
`U.S. application No. 09/470,434, filed Dec. 22, 1999, copy
`U.S. application No. 09/470,434, filed Dec. 22, 1999, copy
`of claims enclosed.
`of claims enclosed.
`U.S. application No. 09/470,427, filed Dec. 22, 1999, copy
`U.S. application No. 09/470,427, filed Dec. 22, 1999, copy
`of claims enclosed.
`of claims enclosed.
`-
`-
`(List continued on next page.)
`(List continued on next page.)
`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 high speed spindle motor is constructed from a stator
`A high speed spindle motor is constructed from a stator
`assembly that includes a stator having multiple conductors
`assembly that includes a stator having multiple conductors
`that create a plurality of magnetic fields when electrical
`that create a plurality of magnetic fields when electrical
`current is conducted by the conductors and a body of a phase
`current is conducted by the conductors and a body of a phase
`change material, such as a thermoplastic, substantially
`change material, such as a thermoplastic, substantially
`encapsulating the stator. A rotatable hub having a magnet
`encapsulating the stator. A rotatable hub having a magnet
`connected thereto is in operable proximity to the stator. The
`connected thereto is in operable proximity to the stator. The
`high speed motor also includes a shaft, a bearing surround
`high speed motor also includes a shaft, a bearing surround(cid:173)
`ing the shaft and one of the bearing or shaft being fixed to
`ing the shaft and one of the bearing or shaft being fixed to
`the stator assembly and the other of the bearing or shaft
`the stator assembly and the other of the bearing or shaft
`being fixed to the rotatable hub. Hard disc drives using the
`being fixed to the rotatable hub. Hard disc drives using the
`motor, and methods of developing and constructing the
`motor, and methods of developing and constructing the
`motor and hard disc drives are also disclosed.
`motor and hard disc drives are also disclosed.
`
`12 Claims, 13 Drawing Sheets
`12 Claims, 13 Drawing Sheets
`
`Am. Honda v. IV II - IPR2018-00443
`PET_HONDA_1014-0001
`
`

`

`US 6,362,554 B1
`US 6,362,554 BI
`Page 2
`Page 2
`
`FOREIGN PATENT DOCUMENTS
`FOREIGN PATENT DOCUMENTS
`
`of claims enclosed.
`
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`3/1995
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`5,400,218 A 3/1995 Val ...........
`… 301/70°
`of claims enclosed.
`Val
`............................ 361/709
`5,400,218 A
`3/1995
`of claims enclosed.
`sº. A ?º º *... Us, application No. 09470433, filed Dec. 22, 1999, copy
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`5/1995
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`10/1995
`of claims enclosed.
`
`; , ;... ." "... ... is application No. 09470.425, filed Dec. 22, 1999, copy
`2 * ~ * > *
`* ~ * *
`* *-*t ? ~ * ~ * *** * * * * * * * * * * * * * * * * * * * * * * * * * * * * *
`Boutaghou et al. ...... 360/99.08
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`3/1996
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`5,506,458 A
`4/1996
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`7/1996 Jabbari et al. ........... 360/97.01
`of claims enclosed.
`of claims enclosed.
`Jabbari et al.
`........... 360/97.01
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`7/1996
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`U.S. application No. 09/470,426, filed Dec. 22, 1999, copy
`Pelstring et al. ......... 360/99.08
`5,548,458 A
`8/1996
`of claims enclosed.
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`of claims enclosed.
`Chen et al. ................. 389/132
`5,558,445 A
`9/1996
`5,579,188 A 11/1996 Dunfield et al. ......... 360/99.08
`U.S. application No. 09/470,424, filed Dec. 22, 1999, copy
`U.S. application No. 09/470,424, filed Dec. 22, 1999, copy
`Dunfield et al. ......... 360/99.08
`5,579,188 A
`11/1996
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`12/1996
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`310/90.5
`of claims enclosed.
`of claims enclosed.
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`5,598,048 A
`1/1997
`sº º !: º: et !
`-- sº U.S. application No. 09/738,268, filed Dec. 15, 2000, copy
`U.S. application No. 091738,268, filed Dec. 15, 2000, copy
`soijoss A ; B. : . º: of application as originally filed enclosed.
`Dunfield et al. ........... 310/90.5
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`3/1997
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`4/1997
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`Product Information from Dupont Engineering Polymers
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`4/1997
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`4/1997
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`tion,” (no date), Publ. Reorder No.: H-58633 (R, 96.7), 20
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`5/1997
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`9/1997
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`9/1997
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`9/1997
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`10/1997
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`... 31997...
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`12/1997
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`3/1998
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`3/1998 Dumfield et al... 360900s
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`4/1998
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`... 264/272.15
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`6/1998
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`2
`Yamano
`...................... 310/91
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`7/1998
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`12/1998
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`... 310/90.5
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`duitTM Thermally Conductive Composites," undated (2
`5,958,466 A
`Ong ........................... 425/127
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`pages).
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`10/1999
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`11/1999
`
`Am. Honda v. IV II - IPR2018-00443
`PET_HONDA_1014-0002
`
`

`

`u.s. Patent
`U.S. Patent
`
`Mar. 26, 2002
`Mar. 26, 2002
`
`Sheet 1 of 13
`Sheet 1 of 13
`
`US 6,362,554 BI
`US 6,362,554 B1
`
`
`
`I--a:::
`(9~
`_0
`LL~
`
`Am. Honda v. IV II - IPR2018-00443
`PET_HONDA_1014-0003
`
`

`

`u.s. Patent
`U.S. Patent
`
`Mar. 26, 2002
`Mar. 26, 2002
`
`Sheet 2 of 13
`Sheet 2 of 13
`
`US 6,362,554 BI
`US 6,362,554 B1
`
`
`
`.
`(9
`
`Am. Honda v. IV II - IPR2018-00443
`PET_HONDA_1014-0004
`
`

`

`u.s. Patent
`U.S. Patent
`
`Mar. 26, 2002
`Mar. 26,2002
`
`Sheet 3 of 13
`Sheet 3 of 13
`
`US 6,362,554 B1
`US 6,362,554 BI
`
`FIG.4
`
`II . / 15 44
`13
`.
`
`26
`
`110 J
`
`?n-___ 114
`
`A~_ 160
`
`FIG.6
`
`
`
`º º
`
`
`
`
`
`
`
`Z
`
`
`
`Am. Honda v. IV II - IPR2018-00443
`PET_HONDA_1014-0005
`
`

`

`u.s. Patent
`U.S. Patent
`
`Mar. 26, 2002
`Mar. 26, 2002
`
`Sheet 4 of 13
`Sheet 4 of 13
`
`US 6,362,554 B1
`US 6,362,554 BI
`
`
`
`o
`
`L()
`
`<.9 -LL
`
`Am. Honda v. IV II - IPR2018-00443
`PET_HONDA_1014-0006
`
`

`

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`U.S. Patent
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`
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`Mar. 26, 2002
`Mar. 26, 2002
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`Sheet 5 of 13
`Sheet 5 of 13
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`US 6,362,554 B1
`US 6,362,554 BI
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`Am. Honda v. IV II - IPR2018-00443
`PET_HONDA_1014-0007
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`

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`u.s. Patent
`U.S. Patent
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`
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`Mar. 26, 2002
`Mar. 26, 2002
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`Sheet 6 of 13
`Sheet 6 of 13
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`US 6,362,554 BI
`US 6,362,554 B1
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`Am. Honda v. IV II - IPR2018-00443
`PET_HONDA_1014-0008
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`u.s. Patent
`U.S. Patent
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`Mar. 26, 2002
`Mar. 26,2002
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`Sheet 7 of 13
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`US 6,362,554 B1
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`u.s. Patent
`U.S. Patent
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`Mar. 26,2002
`Mar. 26, 2002
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`Sheet 8 of 13
`Sheet 8 of 13
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`US 6,362,554 BI
`US 6,362,554 B1
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`u.s. Patent
`U.S. Patent
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`Mar. 26, 2002
`Mar. 26, 2002
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`Sheet 9 of 13
`Sheet 9 of 13
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`US 6,362,554 BI
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`FIG. 12
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`Am. Honda v. IV II - IPR2018-00443
`PET_HONDA_1014-0011
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`

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`u.s. Patent
`U.S. Patent
`
`Mar. 26, 2002
`Mar. 26,2002
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`Sheet 10 of 13
`Sheet 10 of 13
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`US 6,362,554 BI
`US 6,362,554 B1
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`Mar. 26,2002
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`Sheet 11 of 13
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`US 6,362,554 BI
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`Am. Honda v. IV II - IPR2018-00443
`PET_HONDA_1014-0013
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`Sheet 12 of 13
`Sheet 12 of 13
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`US 6,362,554 BI
`US 6,362,554 B1
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`Mar. 26, 2002
`Mar. 26,2002
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`u.s. Patent
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`US 6,362.554 B1
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`1
`1
`STATOR ASSEMBLY
`STATOR ASSEMBLY
`
`REFERENCE TO EARLIER FILED
`REFERENCE TO EARLIER FILED
`APPLICATION
`APPLICATION
`The present application claims the benefit of the filing
`The present application claims the benefit of the filing
`date under 35 U.S.C. §119(e) of provisional U.S. patent
`date under 35 U.S.c. §119(e) of provisional U.S. patent
`application Ser. No. 60/146,446, filed Jul. 29, 1999, which
`application Ser. No. 60/146,446, filed Jul. 29, 1999, which
`is hereby incorporated by reference.
`is hereby incorporated by reference.
`
`FIELD OF THE INVENTION
`FIELD OF THE INVENTION
`The present invention relates generally to a high speed
`The present invention relates generally to a high speed
`motor. It relates particularly to a spindle motor such as used
`motor. It relates particularly to a spindle motor such as used
`in a hard disc drive, and to the construction and arrangement
`in a hard disc drive, and to the construction and arrangement
`of the body of the spindle motor to align and retain the
`of the body of the spindle motor to align and retain the
`respective component parts of the motor, as well as stator
`respective component parts of the motor, as well as stator
`assemblies used in the motors and hard disc drives using the
`assemblies used in the motors and hard disc drives using the
`motors, and methods of developing and manufacturing high
`motors, and methods of developing and manufacturing high
`speed motors.
`speed motors.
`
`2
`2
`the parts, as well as the overall tolerance that relates to the
`the parts, as well as the overall tolerance that relates to the
`alignment of the parts relative to one another.
`alignment of the parts relative to one another.
`In an effort to enable increased motor speed, some hard
`In an effort to enable increased motor speed, some hard
`disc manufacturers have turned to the use of hydrodynamic
`disc manufacturers have turned to the use of hydrodynamic
`bearings. These hydrodynamic bearings, however, have dif
`bearings. These hydrodynamic bearings, however, have dif(cid:173)
`ferent aspect ratios from conventional bearings. An example
`ferent aspect ratios from conventional bearings. An example
`of a different aspect ratio may be found in a cylindrical
`of a different aspect ratio may be found in a cylindrical
`hydrodynamic bearing in which the length of the bearing is
`hydrodynamic bearing in which the length of the bearing is
`greater than it’s diameter. This results in more susceptibility
`greater than it's diameter. This results in more susceptibility
`to problems induced by differing coefficients of thermal
`10
`10 to problems induced by differing coefficients of thermal
`expansion than other metals used in existing spindle motors,
`expansion than other metals used in existing spindle motors,
`making it difficult to maintain dimensional consistency over
`making it difficult to maintain dimensional consistency over
`the operating temperature that the drive sees between the
`the operating temperature that the drive sees between the
`hydrodynamic bearings and other metal parts of the motor.
`hydrodynamic bearings and other metal parts of the motor.
`Hydrodynamic bearings have less stiffness than conven
`15
`15 Hydrodynamic bearings have less stiffness than conven(cid:173)
`tional ball bearings so they are more susceptible to imprecise
`tional ball bearings so they are more susceptible to imprecise
`rotation when exposed to vibrations or shock.
`rotation when exposed to vibrations or shock.
`An important characteristic of a hard drive is the amount
`An important characteristic of a hard drive is the amount
`of information that can be stored on a disc. One method to
`of information that can be stored on a disc. One method to
`20
`store more information on a disc is to place data tracks more
`20 store more information on a disc is to place data tracks more
`BACKGROUND OF THE INVENTION
`BACKGROUND OF THE INVENTION
`closely together. Presently this spacing between portions of
`closely together. Presently this spacing between portions of
`Computers commonly use disc drives for memory storage
`information is limited due to vibrations occurring during the
`Computers commonly use disc drives for memory storage
`information is limited due to vibrations occurring during the
`purposes. Disc drives include a stack of one or more
`operation of the motor. These vibrations can be caused when
`purposes. Disc drives include a stack of one or more
`operation of the motor. These vibrations can be caused when
`magnetic discs that rotate and are accessed using a head or
`the stator windings are energized, which results in vibrations
`magnetic discs that rotate and are accessed using a head or
`the stator windings are energized, which results in vibrations
`25
`read-write transducer. Typically, a high speed motor such as
`of a particular frequency. These vibrations also occur from
`read-write transducer. Typically, a high speed motor such as
`25 of a particular frequency. These vibrations also occur from
`a spindle motor is used to rotate the discs.
`harmonic oscillations in the hub and discs during rotation,
`a spindle motor is used to rotate the discs.
`harmonic oscillations in the hub and discs during rotation,
`caused primarily by non-uniform size media discs.
`caused primarily by non-uniform size media discs.
`An example of a conventional spindle motor 1 is shown
`An example of a conventional spindle motor 1 is shown
`An important factor in motor design is the lowering of the
`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
`An important factor in motor design is the lowering of the
`operating temperature of the motor. Increased motor tem
`made from die cast aluminum, a stator 4, a shaft 6, bearings
`30 operating temperature of the motor. Increased motor tem(cid:173)
`made from die cast aluminum, a stator 4, a shaft 6, bearings
`30
`perature affects the electrical efficiency of the motor and
`7 and a disc support member 8, also referred to as a hub. A
`perature affects the electrical efficiency of the motor and
`7 and a disc support member 8, also referred to as a hub. A
`bearing life. As temperature increases, resistive loses in wire
`magnet 3 and flux return ring 5 are attached to the disc
`bearing life. As temperature increases, resistive loses in wire
`magnet 3 and flux return ring 5 are attached to the disc
`increase, thereby reducing total motor power. Furthermore,
`support member 8. The stator 4 is separated from the base 2
`support member 8. The stator 4 is separated from the base 2
`increase, thereby reducing total motor power. Furthermore,
`using an insulator (not shown) and attached to the base 2
`the Arhennius equation predicts that the failure rate of an
`using an insulator (not shown) and attached to the base 2
`the Arhennius equation predicts that the failure rate of an
`electrical device is exponentially related to its operating
`using a glue. Distinct structures are formed in the base 2 and
`35 electrical device is exponentially related to its operating
`using a glue. Distinct structures are formed in the base 2 and
`35
`temperature. The frictional heat generated by bearings
`the disc support member 8 to accommodate the bearings 7.
`the disc support member 8 to accommodate the bearings 7.
`temperature. The frictional heat generated by bearings
`increases with speed. Also, as bearings get hot they expand,
`One end of the shaft 6 is inserted into the bearing 7
`One end of the shaft 6 is inserted into the bearing 7
`increases with speed. Also, as bearings get hot they expand,
`and the bearing cages get stressed and may deflect, causing
`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
`and the bearing cages get stressed and may deflect, causing
`placed in the bearing 7 located in the hub 8. A separate
`non-uniform rotation and the resultant further heat increase,
`non-uniform rotation and the resultant further heat increase,
`placed in the bearing 7 located in the hub 8. A separate
`non-uniform rotation requiring greater spacing in data
`electrical connector 9 may also be inserted into the base 2.
`electrical connector 9 may also be inserted into the base 2.
`40 non-uniform rotation requiring greater spacing in data
`40
`tracks, and reduced bearing life. One drawback with existing
`tracks, and reduced bearing life. One drawback with existing
`Each of these parts must be fixed at predefined tolerances
`Each of these parts must be fixed at predefined tolerances
`motor designs is their limited effective dissipation of the
`motor designs is their limited effective dissipation of the
`with respect to one another. Accuracy in these tolerances can
`with respect to one another. Accuracy in these tolerances can
`heat, and difficulty in incorporating heat sinks to aid in heat
`significantly enhance motor performance.
`heat, and difficulty in incorporating heat sinks to aid in heat
`significantly enhance motor performance.
`dissipation. In addition, in current motors the operating
`dissipation. In addition, in current motors the operating
`In operation, the disc stack is placed upon the hub. The
`In operation, the disc stack is placed upon the hub. The
`temperatures generally increase as the size of the motor is
`45 temperatures generally increase as the size of the motor is
`stator windings are selectively energized and interact with
`stator windings are selectively energized and interact with
`45
`decreased.
`decreased.
`the permanent magnet to cause a defined rotation of the hub.
`the permanent magnet to cause a defined rotation of the hub.
`Manufacturers have established strict requirements on the
`As hub 8 rotates, the head engages in reading or writing
`Manufacturers have established strict requirements on the
`As hub 8 rotates, the head engages in reading or writing
`outgassing of materials that are used inside a hard disc drive.
`outgassing of materials that are used inside a hard disc drive.
`activities based upon instructions from the CPU in the
`activities based upon instructions from the CPU in the
`These requirements are intended to reduce the emission of
`These requirements are intended to reduce the emission of
`computer.
`computer.
`materials onto the magnetic media or heads during the
`materials onto the magnetic media or heads during the
`Manufacturers of disc drives are constantly seeking to
`Manufacturers of disc drives are constantly seeking to 50
`50
`operation of the drive. Of primary concern are glues used to
`operation of the drive. Of primary concern are glues used to
`improve the speed with which data can be accessed. To an
`improve the speed with which data can be accessed. To an
`attach components together, varnish used to insulate wire,
`attach components together, varnish used to insulate wire,
`extent, this speed depends upon the speed of the spindle
`extent, this speed depends upon the speed of the spindle
`and epoxy used to protect steel laminations from oxidation.
`and epoxy used to protect steel laminations from oxidation.
`motor, as existing magneto-resistive head technology is
`motor, as existing magneto-resistive head technology is
`In addition to such outgassed materials, airborne particu
`capable of accessing data at a rate greater than the speed
`In addition to such outgassed materials, airborne particu(cid:173)
`capable of accessing data at a rate greater than the speed
`late in a drive may lead to head damage. Also, airborne
`offered by the highest speed spindle motor currently in
`late in a drive may lead to head damage. Also, airborne
`offered by the highest speed spindle motor currently in 55
`55
`particulates in the disc drive could interfere with signal
`production. The speed of the spindle motor is dependent
`particulates in the disc drive could interfere with signal
`production. The speed of the spindle motor is dependent
`transfer between the read/write head and the media. To
`transfer between the read/write head and the media. To
`upon the dimensional consistency or tolerances between the
`upon the dimensional consistency or tolerances between the
`r