U.S. patent application number 14/795822 was filed with the patent office on 2016-01-14 for motor interconnect device.
The applicant listed for this patent is Apple Inc.. Invention is credited to Anthony Joseph Aiello, Brad Lee Patton.
Application Number | 20160013696 14/795822 |
Document ID | / |
Family ID | 55067250 |
Filed Date | 2016-01-14 |
United States Patent
Application |
20160013696 |
Kind Code |
A1 |
Aiello; Anthony Joseph ; et
al. |
January 14, 2016 |
MOTOR INTERCONNECT DEVICE
Abstract
A fan assembly having a reduced dimension formed by several
modifications is described. The fan assembly includes a stator
having stator coils positioned within a recessed portion of a
pillow that receives the motor. The stator may include wire
connections positioned between adjacent stator coils and designed
to terminate wires of the stator coils. The wire terminations may
be on a protrusion or a post positioned between adjacent stator
coils, or alternatively, the wire terminations may be disposed on
protruding features of a bushing. The protrusion may be formed from
an electrically conductive material and electrically connected to a
motor control circuit via a flexible printed circuit. In some
embodiments, the protrusion is part of an electrically neutral
stator bushing having several pins. Also, a gap region between the
bushing and a flange feature is designed to improve an adhesive
joint.
Inventors: |
Aiello; Anthony Joseph;
(Santa Cruz, CA) ; Patton; Brad Lee; (Campbell,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Apple Inc. |
Cupertino |
CA |
US |
|
|
Family ID: |
55067250 |
Appl. No.: |
14/795822 |
Filed: |
July 9, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62022600 |
Jul 9, 2014 |
|
|
|
62023732 |
Jul 11, 2014 |
|
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Current U.S.
Class: |
310/71 ; 29/596;
310/91 |
Current CPC
Class: |
F04D 17/08 20130101;
F04D 25/06 20130101; H02K 3/521 20130101; F04D 25/0613 20130101;
H02K 15/0056 20130101; H02K 5/225 20130101; F04D 29/646 20130101;
H05K 7/20136 20130101; G06F 1/203 20130101; H02K 5/04 20130101;
H01F 6/06 20130101; H02K 2203/03 20130101; H02K 3/46 20130101 |
International
Class: |
H02K 3/46 20060101
H02K003/46; H01F 6/06 20060101 H01F006/06; F04D 25/06 20060101
F04D025/06; H02K 5/04 20060101 H02K005/04; F04D 17/08 20060101
F04D017/08; H02K 15/00 20060101 H02K015/00; H02K 5/22 20060101
H02K005/22 |
Claims
1. A fan assembly suitable for use in a computing system, the fan
assembly comprising: a stator including a first stator pole and a
second stator pole; a coil wound around the first stator pole and
the second stator pole to define a first stator coil and a second
stator coil, the coil including a wire portion; and a circuit
assembly including a post positioned between the first stator coil
and the second stator coil, the post having an electrically
conductive region that receives the wire portion to electrically
connect the first stator coil with the circuit assembly.
2. The fan assembly of claim 1, further comprising a pillow having
a recessed portion that receives a portion of the first stator
coil.
3. The fan assembly of claim 2, wherein the pillow further
comprises an opening extending through the pillow, and wherein the
circuit assembly extends through the opening to electrically couple
with a component.
4. The fan assembly of claim 2, wherein the circuit assembly
comprises an extension that receives the post.
5. The fan assembly of claim 1, further comprising a bushing
adhesively secured with the stator to define an adhesive joint that
increases in size in a radially outward direction from a center of
the bushing.
6. The fan assembly of claim 5, wherein the bushing is adhesively
secured with the stator to define an adhesive joint that gradually
increases in thickness in a radially outward direction.
7. The fan assembly of claim 1, wherein the post comprises an
exterior region formed from a non-electrically conductive
material.
8. A method for reducing a dimension of a fan motor assembly of an
electronic device, the method comprising: positioning a plurality
of coils of the fan motor assembly within a recessed portion of a
pillow, the plurality of coils wound around a first stator pole and
a second stator pole of a stator; and terminating a wire portion of
the plurality of coils between the first stator pole and the second
stator pole.
9. The method of claim 8, further comprising electrically
connecting the plurality of coils to a post disposed on a printed
circuit assembly, the printed circuit assembly electrically
connected a motor control circuit located externally with respect
to the fan motor assembly.
10. The method of claim 9, wherein the post comprises an insulating
material.
11. The method of claim 8, further comprising electrically
connecting the plurality of coils to a pin positioned partially
within a protruding feature of a bushing, wherein the protruding
feature is positioned between the first stator pole and the second
stator pole.
12. The method of claim 11, wherein the pin extends through the
protruding feature and electrically connects with a printed circuit
assembly.
13. The method of claim 12, wherein the pin extends through the
pillow.
14. The method of claim 11, wherein the protruding feature is
integrally formed with the bushing.
15. A fan assembly suitable for use in a computing system, the fan
assembly comprising: a stator comprising: a first stator pole
having a first stator coil; and a second stator pole having a
second stator coil; a bushing having a protruding feature extending
from the bushing and disposed between the first stator coil and the
second stator coil, the protruding feature comprising a pin
extending through the protruding feature; and a pillow that
receives the bushing and comprises an opening, wherein the pin
extends through the opening.
16. The fan assembly of claim 15, wherein the first stator coil
comprises a wire portion electrically connected with the pin at a
first end, and wherein the pin comprises a second end opposite the
first end, the second end extending through the opening of the
pillow.
17. The fan assembly of claim 16, wherein: the pillow comprises a
first surface that receives the bushing, the pillow comprises a
second surface opposite the first surface, and the second end of
the pin is electrically connected with a component disposed
proximate to the second surface.
18. The fan assembly of claim 15, wherein the pillow comprises a
flange feature adhesively secured with the bushing to define an
adhesive joint that includes a graduated gap between the bushing
and the flange feature, the graduated gap increasing radially
outward from a center of the bushing.
19. The fan assembly of claim 15, wherein the protruding feature
includes a non-electrically conductive material to electrically
insulate the pin.
20. The fan assembly of claim 15, further comprising a first
recessed portion that receives the first stator coil, and a second
recessed portion that receives the second stator coil.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims the benefit of priority under 35
U.S.C. .sctn.119(e) to U.S. Provisional Application No. 62/022,600,
filed on Jul. 9, 2014, and titled "MOTOR INTERCONNECT DEVICE," and
to U.S. Provisional Application No. 62/023,732, filed on Jul. 11,
2014, and titled "MOTOR INTERCONNECT DEVICE," the disclosures of
which are incorporated herein by reference in its entirety.
FIELD
[0002] The described embodiments relate generally to a component
within an electronic device. In particular, the present embodiments
relate to an electronic device having a motor with a reduced height
which may allow for reduced dimensions of the electronic
device.
BACKGROUND
[0003] Centrifugal fans are commonly used in computing systems and
other electronic devices to provide cooling of the central
processing unit (CPU), graphics processing unit (GPU) and/or other
modules. Newer product generations typically introduce new features
and/or faster processors that offer improved computing performance.
Additionally, in the area of portable electronic devices, reduction
in the overall thickness of the computer, particularly the
enclosure, is a common goal for improving portability and customer
appeal. In order to compensate for a smaller enclosure, a cooling
fan may include a fan having a reduced motor height, which can
compromise the motor performance.
[0004] However, as a result of these upgrades, higher thermal
loading may be imposed on the system, which consequently requires
increased airflow from the cooling fan to avoid overheating or
throttling of processor performance to stay within sustainable
temperature ranges. Also, as enclosures of portable electronic
devices continue to have reduced dimensions, airflow through
enclosures becomes highly impeded, resulting in increased demands
on the cooling fan while at the same time requiring that the fan
conform to the dimensions of the enclosure. Unfortunately, a
cooling fan with a motor of reduced height corresponds to a fan
having less torque delivery. Also, simply reducing the size of
traditional cooling fans compromises the space needed to
accommodate an electrical connection means for the fan motor.
[0005] Further, as enclosures of the computing systems become
thinner, the space allocated for the motor and bearing is reduced,
resulting in less space for mechanical attachment means. Any
compromise on the impeller attachment to the pillow or base of the
fan can result in reduced shock robustness, which is also a
critical requirement of portable computing systems.
SUMMARY
[0006] In one aspect, a fan assembly is described. The fan assembly
may include a bushing that includes a channel. The fan assembly may
further include a pillow having a flange feature extending into the
channel. In some embodiments, the flange feature includes a first
axial surface separated from a first surface of the channel by a
first gap distance and a second axial surface separated from a
second surface of the channel by a second gap distance different
from the first gap distance. Also, the second surface may be
different from the first surface.
[0007] In another aspect, a fan assembly having a longitudinal axis
that extends through a center of the fan assembly is described. The
fan assembly may include a pillow comprising a pillow interface
surface. The fan assembly may further include a bushing that
extends circumferentially around the longitudinal axis and having a
bushing interface surface that cooperates with the pillow interface
surface defining an interface channel comprising an axial channel
component that is parallel to the longitudinal axis. In some
embodiments, the interface channel includes an axial channel
component having a width, or thickness, that varies in accordance
with a radial distance from the longitudinal axis.
[0008] In another aspect, a fan assembly suitable for use in a
portable computing system is described. The fan assembly may
include a pillow including a flange portion. The fan assembly may
further include a cover secured with the pillow. The cover may
include a channel that receives the flange portion. The fan
assembly may further include an adhesive disposed in the channel to
adhesively secure the cover with the pillow. In some embodiments,
the adhesive includes a graduated thickness.
[0009] In another aspect, a fan assembly suitable for use in a
portable computing system is described. The fan assembly may
include a first part including a flange portion. The fan assembly
may further include a second part secured with the first part. The
second part may include a channel that receives the flange portion.
The fan assembly may further include a first clearance formed by a
gap between an inner surface to the flange portion and the surface
facing the channel and a second clearance formed by the gap between
the outer surface of the flange portion and another facing surface
of the channel. The first clearance and the second clearance may
run parallel to each other. The fan assembly may further an
adhesive disposed in both the first clearance and the second
clearance and disposed to adhesively secure the second part with
the first part.
[0010] Other systems, methods, features and advantages of the
embodiments will be, or will become, apparent to one of ordinary
skill in the art upon examination of the following figures and
detailed description. It is intended that all such additional
systems, methods, features and advantages be included within this
description and this summary, be within the scope of the
embodiments, and be protected by the following claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The disclosure will be readily understood by the following
detailed description in conjunction with the accompanying drawings,
wherein like reference numerals designate like structural elements,
and in which:
[0012] FIG. 1 illustrates an isometric view of a fan assembly;
[0013] FIG. 2 illustrates a partial cross sectional view of the fan
assembly in FIG. 1, taken along line 2-2;
[0014] FIG. 3 illustrates an isometric view of an embodiment of an
electronic device in an open configuration;
[0015] FIG. 4 illustrates an isometric view of a fan assembly in
accordance with the described embodiments;
[0016] FIG. 5 illustrates a plan view of an internal portion of a
top case of an electronic device having a fan assembly positioned
within the internal portion, in accordance with the described
embodiments;
[0017] FIG. 6 illustrates a partial cross sectional view of a fan
assembly shown in FIG. 4 taken along line 6-6, in accordance with
the described embodiments;
[0018] FIG. 7 illustrates an isometric top view of the bushing, in
accordance with the described embodiments;
[0019] FIG. 8 illustrates an isometric bottom view of the bushing
shown in FIG. 7;
[0020] FIG. 9 illustrates a cross sectional view between the
bushing (shown in FIGS. 7 and 8) and a pillow;
[0021] FIG. 10 illustrates an isometric view of an embodiment of a
pillow designed to receive a fan assembly;
[0022] FIG. 11 illustrates a plan view of an alternate embodiment
of a fan assembly, in accordance with the described
embodiments;
[0023] FIG. 12 illustrates a partial isometric view of the fan
assembly show in FIG. 11 showing additional features of the pillow
and the cover;
[0024] FIG. 13 illustrates a cross sectional view of the fan
assembly shown in FIGS. 11 and 12, further showing the pillow
adhesively secured with the cover;
[0025] FIG. 14 illustrates an isometric view of an embodiment of a
stator having coils with wires electrically connected with
protrusions attached to a flexible printed circuit assembly;
[0026] FIG. 15 illustrates an isometric view of an embodiment of a
printed circuit assembly having posts as well as an elongated
portion designed to electrically connect with another
component;
[0027] FIG. 16 illustrates an isometric view of an embodiment of a
stator surrounding a bushing, in accordance with the described
embodiments;
[0028] FIG. 17 illustrates a top view of an embodiment of a stator
bushing having connections points for wire termination;
[0029] FIG. 18 illustrates a bottom view of the stator bushing
shown in FIG. 17, in accordance with the described embodiments;
[0030] FIG. 19 illustrates an isometric view of a stator and stator
bushing assembled with a pillow of an electronic device, in
accordance with the described embodiments; and
[0031] FIG. 20 illustrates a flowchart showing a method for
reducing a dimension of a motor.
[0032] Those skilled in the art will appreciate and understand
that, according to common practice, various features of the
drawings discussed below are not necessarily drawn to scale, and
that dimensions of various features and elements of the drawings
may be expanded or reduced to more clearly illustrate the
embodiments of the present invention described herein.
DETAILED DESCRIPTION
[0033] Reference will now be made in detail to representative
embodiments illustrated in the accompanying drawings. It should be
understood that the following descriptions are not intended to
limit the embodiments to one preferred embodiment. To the contrary,
it is intended to cover alternatives, modifications, and
equivalents as can be included within the spirit and scope of the
described embodiments as defined by the appended claims.
[0034] In the following detailed description, references are made
to the accompanying drawings, which form a part of the description
and in which are shown, by way of illustration, specific
embodiments in accordance with the described embodiments. Although
these embodiments are described in sufficient detail to enable one
skilled in the art to practice the described embodiments, it is
understood that these examples are not limiting such that other
embodiments may be used, and changes may be made without departing
from the spirit and scope of the described embodiments.
[0035] FIG. 1 illustrates an isometric view of a fan assembly 100
that may be disposed within an electronic device, such as a laptop
computing device. The fan assembly 100 can include a cover 102 that
conceals a portion of an impeller 104. FIG. 2 illustrates a partial
cross sectional view of the fan assembly 100 shown in FIG. 1, taken
along the line 2-2. As shown, the fan assembly 100 includes various
structural components, which may limit the ability to reduce its
overall size, and in turn, limits the ability to reduce a size or
dimension of an electronic device that includes the fan assembly
100. For example, the motor hub 108 and the printed circuit 124 are
separated by a clearance region defined by a distance 130 shown in
a z-direction. The distance 130 is due in part to the dimension of
a first stator coil 118 and a second stator coil 120, both of which
are attached to a stator 114. Also, each of the stator coils
includes a wire portion that terminates in a location between the
motor hub 108 (along with a portion of a magnet 122) and the
printed circuit 124. For example, the wire portion 126 of the first
stator coil 118 is terminated, via solder 128, between the motor
hub 108 and the printed circuit 124. The presence of the solder 128
between the motor hub 108 and the printed circuit 124 may limit how
close the motor hub 108 and the printed circuit 124, which may
affect the overall height 132 of the fan assembly.
[0036] In addition, the fan assembly 100 is secured to a pillow 112
(or base). This is achieved by adhesively securing an outer surface
of the bushing 116 to an inner surface of a flange feature 142 of
the pillow 112. As shown in FIG. 1, 1) the bushing 116 extends
circumferentially around a longitudinal axis 162 extending through
the center of rotation of the fan assembly 100, and 2) the flange
feature 142 extends circumferentially around the bushing 116. In
order to center an impeller (not shown) used with the fan assembly
100, the inner surface of the flange feature 142 registers against
the outer surface of the bushing 116. The function of centering the
fan assembly 100 requires a small radial gap and a bond line
thickness of the adhesive filling this radial gap may not be
optimal for maximizing the joint strength. Adhesives used for these
types of joints typically have peak strength when the bond line is
approximately 0.05-0.1 millimeters (mm) thick. For this reason, the
bushing 116 includes a circumferential groove 144 (shown in the
enlarged view) in which the radial gap is closer to the optimal
bond line thickness for whatever adhesive is chosen. This results
in an even smaller "effective" axial length (in the direction of
the longitudinal axis 162) of the adhesive joint, resulting is
greatly diminished joint strength.
[0037] In the present disclosure, the described embodiments allow
for reducing a dimension of a fan assembly while maintaining the
integrity (e.g., torque delivery) of the fan assembly. In
particular, a thickness, or z-height, of the fan assembly may be
reduced in order to form a more compact form factor. Although
reducing the dimension of the fan assembly reduces space for
components, the components in the present disclosure are
redesigned. For example, a fan assembly may use space between
coils, which is traditionally unused space, in order to
electrically connect coil lead wires to another component.
Traditional connection of lead wires of a stator coil may be
performed below a component (e.g., magnet) of the fan assembly
using an operation such as soldering. However, in the present
disclosure the lead wires are connected in different locations such
that a motor hub may be repositioned, i.e., lowered, to a location
previously occupied by traditional connection means of the lead
wires. Also, because the connection is performed in the previously
unused space, little, if any, modification or retrofitting of other
components is required.
[0038] Also, in some embodiments, a pillow (or substrate)
positioned below the fan assembly may include one or more recessed
portions that receives the stator coils. In some embodiments, the
pillow is formed from an injection molding operation in which the
recessed portions are formed during formation of the pillow. In
other embodiments, the recessed portions formed subsequent to
formation of the pillow. In this manner, the recessed portions may
be formed by a material removal operation. In either event, the
recessed portions of the pillow may define an annular (or ring)
shape. Alternatively, the recessed portions may define several
individual recessed portions of the pillow, with the number of
recessed portions corresponding to the number of stator coils.
Also, the recessed portions may include a size and a shape to
receive a portion of the stator coils.
[0039] Further, the present disclosure describes adhesive joints
which may compensate for fan motor assemblies having a reduced size
which in turn includes reduced surface area to form the adhesive
joint. In this regard, a bushing of the fan assembly may be
modified to receive a flange feature of the pillow. Further, the
gap region defined by a space between the bushing and the flange
region may include varying gap distances. For example, the gap
region may include a first gap distance and a second gap distance
greater than the first gap distance. In this manner, the strength
of the adhesive joint formed in the gap region may be substantially
increased, and the fan assembly is more resistant to load bearing
events even in instances when the electronic device (that includes
the fan assembly) includes a reduced size.
[0040] These and other embodiments discussed below with reference
to FIGS. 3-19 illustrate a motor having a reduced dimension but
without reduced performance (e.g., reduced torque delivery).
However, those skilled in the art will readily appreciate that the
detailed description given herein with respect to these Figures is
for explanatory purposes only and should not be construed as
limiting.
[0041] FIG. 3 illustrates an isometric view of an electronic device
200 in an open configuration. In some embodiments, the electronic
device 200 is a portable electronic device such as a MACBOOK
PRO.RTM., made by Apple, Inc., from Cupertino, Calif. In other
embodiments, the electronic device 200 is a different consumer
electronic device designed to offer and/or display various visual
content. As shown, the electronic device 200 includes a lid portion
202 pivotally connected to a base portion 204, both of which may be
formed from a metal, such as aluminum or aluminum alloy. As shown,
the lid portion 202 includes a display 206 designed to display
visual content such as a graphical user interface, still images
such as photos, as well as video media items such as movies. The
display 206 may be electrically connected with one or more
processors (not shown) in the base portion 204.
[0042] The base portion 204 may include a top case 208. As
illustrated in FIG. 3, the top case 208 is designed to accommodate
various user input devices such as a keyboard 212 and a touchpad
214. In particular, these user input devices may be exposed such
that a user may interact with the input devices when the electronic
device 200 is positioned in the open configuration. Further, the
base portion 204 may include a bottom case (not shown). The bottom
case along with top case 208 may cooperate to receive various other
electronic and mechanical components.
[0043] Although not shown, the electronic device 200 may include
several electronic components such as a mass storage device (e.g.,
a hard drive or a solid state storage device such as a flash memory
device including non-transitory and tangible memory that may be,
for example, volatile and/or non-volatile memory) configured to
store information, data, files, applications, instructions or the
like, a processor (e.g., a microprocessor or controller) configured
to control the overall operation of the portable electronic device,
a communication interface configured for transmitting and receiving
data through, for example, a wired or wireless network such as a
local area network (LAN), a metropolitan area network (MAN), and/or
a wide area network (WAN), for example, the Internet, a fan, a heat
pipe, and one or more batteries.
[0044] FIG. 4 illustrates an isometric view of a fan assembly 300
in accordance with the described embodiments. In some embodiments,
the fan assembly 300 is a centrifugal fan designed to cool several
components within an electronic device (such as the electronic
device 200 shown in FIG. 3). The fan assembly 300 may include a
cover 302 that covers a portion of the impeller 304. The cover 302
may include an opening 306 defining an inlet region for air to flow
through the impeller 304. The fan assembly 300 may further include
a motor hub 308, a bearing 310, and a motor (not shown) below the
motor hub 308. In some embodiments, the motor is a 3-phase
brushless DC motor.
[0045] The fan assembly 300 may further include a pillow 312
designed to receive and hold one or more components of the fan
assembly 300. In some embodiments, the fan assembly 300 is
positioned within a portion of an electronic device such that the
pillow 312 is positioned against an interior portion of a top case
(such as the top case 208 shown in FIG. 3) to form an integrated
system. In some embodiments, the impeller 304 is designed to drive
air received from the opening 306 to heat-dissipating components in
order to cool those components. In other embodiments, the impeller
304 receives heated air from the heat-generating components within
an electronic device via the opening 306, and drive the heated air
along the pillow 312 and/or in a direction toward the outlet region
315 thereby allowing the heated air to escape the electronic
device.
[0046] Also, in some embodiments, the fan assembly 300 includes a
motor control circuit 319 electrically connected with the motor.
The motor control circuit 319 may be configured to drive (or
commutate) electrical current through the stator coils (not shown)
of the motor in order to generate torque used to drive the impeller
304. In some embodiments, the motor control circuit 319 is
positioned within the cover 302 or the motor hub 308. In the
embodiment shown in FIG. 4, the motor control circuit 319 is
external with respect to several components of the fan assembly
300, such as the cover 302, the impeller 304, and the motor hub
308. Also, the motor control circuit 319 may also be external with
respect to the pillow 312. Also, in some embodiments, the motor
control circuit 319 is electrically connected with an input/output
(I/O) board (not shown), which may include a main logic board
(MLB). In this manner, when the motor control circuit 319 is
external to other components of the fan assembly 300, the fan
assembly 300 may include a lower profile (e.g., less thickness in
at least one dimension) without reduced performance. This will be
discussed below. Also, although not shown, the motor control
circuit 319 may be electrically connected with a flexible printed
circuit, which may be at least partially within the cover 302.
[0047] FIG. 5 illustrates a plan view of an internal portion 220 of
the top case 208 (shown in FIG. 3) having a fan assembly 300 (shown
in FIG. 4) positioned within the internal portion 220. In this
configuration, the pillow 312 is positioned proximate to a keyboard
region 222 of the top case 208. However, it should be appreciated
that the fan assembly 300 may be positioned at any suitable
location within an electronic device. Also, the pillow 312 and the
outlet region 315 may be positioned proximate to openings 228 of
top case 208 in order to facilitate the removal of air (such as
heated air) from the electronic device.
[0048] In addition to locating the motor control circuit 319
externally with respect to the fan assembly 300, other additional
configurations may contribute to the fan assembly having a lower
profile. For example, FIG. 6 illustrates a partial cross sectional
view of a fan assembly 300 taken along the 6-6 line in FIG. 4, in
accordance with the described embodiments. In this embodiment, the
fan assembly 300 may include a height 332 in the z-direction less
than a height of fan motor assemblies previously discussed (such as
a height 132 of the fan assembly 100) to define a lower profile of
the fan assembly 300. This may be due in part to the fan assembly
300 including features that may facilitate reduction in the overall
height of the fan assembly. For example, the fan assembly 300 may
include a stator 314 positioned around a bushing 316. In some
embodiments, the stator 314 is formed from several silicon steel
sheets laminated together. The stator 314 may include several
stator coils, such as first stator coil 318 and second stator coil
320, positioned on several stator poles of the stator 314. For
example, the stator in FIG. 6 includes a first stator coil 318 and
a second stator coil 320, each of which include electrically
conducting coils wound around a first stator pole 338 and a second
stator pole 340, respectively. For purposes of clarity, the wire
portions interconnecting the stator coils are not shown. The first
stator coil 318 and the second stator coil 320 are designed to
receive electrical current from a power source (such as a battery
disposed within an electronic device) to form an electromagnet.
[0049] The fan assembly 300 further includes a magnet 322
surrounding the stator coils. The magnet 322 is a multi-polarity
magnet that includes a first polarity and a second polarity
opposite the first polarity. The first polarity and the second
polarity may be associated with a "North" facing polarity and a
"South" facing polarity, respectively, also referred to as a
"north" pole and "south" pole of a magnet. Although not shown, the
magnet 322 may include several pairs that include a "north-south"
configuration. For example, the magnet 322 may include a four-pole
design having two north facing poles and two south facing poles.
Generally, the magnet 322 may include any even number of poles in
which a north pole is paired with a south pole. Also, the magnet
322 may be positioned around an inner circumference of the motor
hub 308, as shown in FIG. 6. When electrical current passes through
the stator coils, the magnet 322, the motor hub 308, and an
impeller (not shown) coupled with the motor hub 308 may be
actuated, or rotated, in order to drive air in a manner previously
described. Also, traditional motors may include a wire connection
(not shown) using solder to connect the wires of the coils in a
location, for example, directly between a magnet (and/or a motor
hub) and a circuit, as shown in FIG. 2. Accordingly, this location
is occupied by both a wire as well as solder, both of which reduce
the ability to minimize the height of a fan assembly. However, by
locating this connection elsewhere within the fan assembly 300
(which will be discussed below), a distance 330 (or clearance)
between the motor hub and a printed circuit assembly 328 is reduced
and in turn a height 332 of the fan assembly 300 is also reduced,
as shown in FIG. 6. It will be appreciated that in some
embodiments, the printed circuit assembly 328 is a flexible printed
circuit. However, the printed circuit assembly 328 may be a
flexible material generally known in the art for electrically
connecting two or more components.
[0050] Further, the pillow 312 includes a region of removed
material to define one or more recessed portions, such as a first
recessed portion 324 and a second recessed portion 326. The
recessed portions are designed to at least partially receive the
stator coils. For example, as shown, first recessed portion 324 and
a second recessed portion 326 receive the first stator coil 318 and
second stator coil 320, respectively. A first enlarged view 376
shows part of first recessed portion 324. In some embodiments, the
recessed portions include a series of openings configured to
receive the stator coils. The holes may be referred to as blind
holes, or counter bores. The number of recessed portions generally
corresponds to the number of stator coils on the stator 314.
However, in other embodiments, one or more recessed portions may be
designed to at least partially receive two or more stator
coils.
[0051] In addition to or as an alternative to the recessed portions
of the pillow 312, the fan assembly 300 may include additional
features to achieve an overall lower profile. For example, fan
motor assemblies include stator coils electrically connected to a
printed circuit via a solder/wire connection located directly
between a printed circuit and a magnet, or directly between a
printed circuit and a motor hub. In the embodiment shown in FIG. 6,
an electrical connection (not shown) between a stator coil and the
printed circuit assembly 328 is in a location other than a location
between the magnet 322 and the printed circuit assembly 328. In
this manner, the motor hub 308 and the magnet 322 may be positioned
closer to the printed circuit assembly 328 contributing to the
distance 330 (or clearance) decreasing to a distance less than that
of traditional fan assemblies.
[0052] Additional modifications may be made to the fan assembly 300
to reduce the overall height in the z-direction. For example, the
motor hub 308 may include an outer peripheral portion 336 shown as
imaginary lines representing a reduced height of motor hub 308 (in
the z-direction). Despite the reduced height, it may be desirable
to form the motor hub 308 reducing its material thickness. For
example, a thickness 337 of the motor hub 308 may not be reduced
when reducing the height 332 of the fan assembly 300. This is
possible due in part by positioning the stator coils within the
recessed portions (previously described) of the pillow 312, thereby
allowing the motor hub 308 to occupy space previously occupied by
the stator coils. The combination of the recessed portions, the
location of the motor control circuit, and the position of the
motor hub 308 in areas previously occupied by the stator coils, the
distance 330 between the motor hub 308 and the printed circuit
assembly 328 is minimized and the fan assembly 300 includes a
height 332 in the z-direction that is lower than traditional fan
motor assemblies.
[0053] Also, the fan assembly 300 may be adhesively secured with
the pillow 312. This may be achieved by adhesively securing the
bushing 316 with a first flange feature 342 and optionally a second
flange feature 344 of the pillow 312. It should be understood that
1) the bushing 316 extends circumferentially around a longitudinal
axis 362 extending through the center of the fan assembly 300, and
2) the first flange feature 342 extends circumferentially around
the bushing 316. The second flange feature 344, when used, may be
designed to receive (and in some cases, align) the stator coils,
and may only extend around portions of the bushing 316. However, in
other embodiments when the second flange feature 344 is not used,
the pillow extends in a generally flat manner to the first flange
feature 342. Further, the longitudinal axis 362 may be referred to
as an axial direction to explain and described one or more axial
interfaces, surfaces or regions. The bushing 316 may be designed to
increase an axial interface region between the bushing 316 and the
first flange feature 342 such that an axial length of an adhesive
joint between the bushing 316 and the first flange feature 342
increases. For example, the second enlarged view 378 shows multiple
axial interface regions between a channel 346 of the bushing 316
and surfaces of the first flange feature 342. As shown, the channel
346 generally surrounds the first flange feature 342 with the
dimensions and tolerances of the channel 346 designed to improve
alignment during assembly of the bushing 316. Traditional assembly
may allow adhesive between only a single axial surface of the first
flange feature 342 and the bushing 316, and may allow for limited
adhesive bonding strength. However with the channel 346 defining a
gap between two axial surfaces of the first flange feature 342, the
channel 346 not only improves alignment between the bushing 316 and
the pillow 312, but also allows an adhesive to flow around both
axial surfaces of the first flange feature 342. In this manner,
multiple adhesive interfaces are formed and the adhesive may form a
stronger adhesive joint. Further, the channel 346 is designed as
part of a radial gap (between the bushing 316 and the features of
the pillow 312) to include a certain gap distance between the
pillow 312 and the bushing 316 to ensure flow of an adhesive (not
shown) between the two structures. Also, the bushing 316 includes a
shoulder region 368 proximate to the second flange feature 344 with
the radial gap extending between the shoulder region 368 and the
second flange feature 344. This may allow for additional flow of
the adhesive to increase an adhesive bond strength. This will be
discussed in further detail below.
[0054] FIGS. 7 and 8 illustrate isometric view of a bushing 416 in
an isolated view, in accordance with the described embodiments. The
bushing 416 shown and described may include any feature or features
previously described for a bushing. FIG. 7 illustrates an isometric
top view of the bushing 416. As shown, the bushing 416 includes an
outer surface 422 designed to engage and align a stator (such as
the stator 314, shown in FIG. 6). Also, an interior region of the
bushing 316 further includes a bore region 424 defined by a space
or void of any material. The bore region 424 is designed to receive
a component of a fan assembly, such as a bearing. The bushing 416
also includes a shoulder portion 426 that may be designed to mate
with a portion of a pillow (such as the first flange feature 342,
shown in FIG. 6). For instance, the shoulder portion 426 may
include a size and a shape to allow an adhesive to flow between the
shoulder portion 426 and a flange feature of the pillow (such as
the second flange feature 344 shown in FIG. 6) in order to form an
adhesive joint. Further, the adhesive joint may include a thickness
based upon the dimensions of the flange feature and/or shoulder
portion 426 to ensure a bond line thickness of a chosen adhesive
that allow the adhesive joint to include sufficient bonding
strength.
[0055] FIG. 8 illustrates an isometric bottom view of the bushing
416. The bushing 416 includes a channel 428 designed to receive a
flange feature (such as the first flange feature 342 shown in FIG.
6) as well as an adhesive. The channel 428 is further designed to
define a part of a gap region to receive an adhesive in order to
form an adhesive joint between the bushing 416 and another
structural feature. The channel 428 may be formed by a material
removal process that includes, for example, a lathe. However, the
channel 428 may be formed during the formation of the bushing 416.
For example, the channel 428 may be formed by injection molding,
die casting, metal injection molding (MIM), all of which may
include a mold cavity that include a shape designed to form the
channel 428.
[0056] The relationship between a bushing and a pillow may be
formed to optimize an adhesive joint designed to bond the bushing
with the pillow. In particular, a radial gap extending between
multiple interface regions of the bushing and features of the
pillow may vary. For example, one portion of the radial gap may
extend between a first bushing surface and a first pillow surface
(or first flange feature surface) and may include a first gap
thickness defined by the separation between the first bushing
surface and the first pillow surface. Another portion of the radial
gap may extend between a second bushing surface and a second pillow
surface and may include a second gap thickness defined by the
separation between the second bushing surface and the second pillow
surface. The second gap thickness may be different (for example,
greater than or less than) the first gap thickness. Also, the
radial gap may include several axial channel components (defined as
interface regions in the axial direction between the bushing and
the pillow) as well as radial channel components (defined as
interface regions in the radial direction between the bushing and
the pillow, and generally perpendicular to the axial channel
components).
[0057] To further describe the relationship, the gap distance
between bushing-pillow surfaces may vary based upon a radial
distance from a center of the bushing. Referring to the example
above, the second bushing surface and the second pillow surface may
be positioned further from the center of the bushing than the first
bushing surface and the first pillow surface. In some embodiments,
the gap distance varies in that the first gap distance is greater
than the second gap distance.
[0058] However, the gap distance varies in that the first gap
distance is less than the second gap distance. For example, FIG. 9
illustrates a cross sectional view between the bushing 416 (shown
in FIGS. 7 and 8) and a pillow 412. The pillow 412 may include
several features previously described for a pillow. For example, as
shown, the pillow 412 includes a first flange feature 442 and an
optionally, may further include a floor feature 444. The enlarged
view illustrates an adhesive 434 extending between the bushing 416
and the pillow 412. As shown, the adhesive 434 is in the channel
428 of the bushing extends around multiple axial surfaces of the
first flange feature 442, with an "axial surface" defined by an
axial direction denoted by the arrow 466. With the adhesive 434
surrounding the first flange feature 442 in a manner shown in FIG.
9, an adhesive joint formed by the adhesive 434 increases the
bonding strength between the bushing 416 and the pillow 412.
[0059] Also, as shown in FIG. 9, the adhesive 434 extends along
additional interface regions. For example, the adhesive 434 may
extend to a location between the floor feature 444 and the shoulder
portion 426 of the bushing 416. In this manner, the adhesive joint
formed by the adhesive 434 secures additional features to increase
the bond between the bushing 416 and the pillow 412. Accordingly,
when the floor feature 444 is included, the floor feature 444 may
act in a manner similar to an additional flange feature and define
an additional axial connect point for an adhesive interface. Also,
while a cross sectional view is shown, it should be understood that
the flange features and the adhesive 434 extend in a generally
circular or circumferential manner.
[0060] In addition to the adhesive 434 extending to multiple
features, the adhesive 434 may vary in thickness according to the
gap distances between the bushing-pillow surface interfaces. In
particular, the variations in thickness may increase in a radially
outward direction (denoted by an arrow 468) from a center of the
bushing 416 to an exterior region of the bushing 416. For example,
as shown in FIG. 9, the adhesive 434 includes a first thickness
defined by a first gap distance 448 between the first flange
feature 442 and the bushing 416. In particular, the first gap
distance 448 may be a distance between a first surface of the
channel 428 and a first surface of the first flange feature 442.
The first gap distance 448 may be referred to as a distance between
the bushing 416 and a first axial surface of the first flange
feature 442 to define a first axial channel, with the axial
direction defined by the arrow 466. Further, the adhesive 434
includes a second thickness defined by a second gap distance 450
between a second surface of the channel 428 and a second surface of
the first flange feature 442, with the second gap distance 450
being greater than the first gap distance 448. The second gap
distance 450 may be referred to as a distance between the bushing
416 and a first radial surface of the first flange feature 442 to
define a first radial channel. Further, the adhesive 434 includes a
third thickness defined by a third gap distance 452 between a third
surface of the channel 428 and a third surface of the first flange
feature 442, with the third gap distance 452 being greater than the
second gap distance 450. The third gap distance 452 may be referred
to as a distance between the bushing 416 and a second axial surface
of the first flange feature 442 to define a second axial channel,
with the axial direction defined by the arrow 466. Accordingly, a
radial gap between the first flange feature 442 of the pillow and a
channel 428 of the bushing 416 includes a graduated radial gap,
that is, a gap that increases in a direction. As shown in FIG. 9,
the direction is a radially outward direction. In addition to
creating an alignment means between the bushing 416 with the pillow
412, the channel 428 allows the adhesive joint formed by the
adhesive 434 to increase around multiple surfaces of the first
flange feature 442, including multiple axial surfaces.
[0061] The adhesive joint formed by the adhesive 434 may extend and
continue to increase in thickness in a radially outward direction.
For example, as shown in FIG. 9, the adhesive 434 includes a fourth
thickness defined by a fourth gap distance 454 between the bushing
416 and the pillow 412, with the fourth gap distance 454 being
greater than the third gap distance 452. The fourth gap distance
454 may also be referred to as a gap between the shoulder portion
426 of the bushing 416 and a surface of a channel region 446
defined by the first flange feature 442 and the floor feature 444.
The fourth gap distance 454 may be referred to as a distance
between the bushing 416 and the channel region 446 between the
first flange feature 442 and the floor feature 444, and defining a
second radial channel. Accordingly, a radial gap between the
bushing 416 and the pillow 412 may be graduated, or increased, in a
radially outward direction from the first flange feature 442 to the
floor feature 444. Also, when the radial gap is includes a desired
graduated configuration (for example, as shown in FIG. 9), the
circumferential groove 460 in the bushing 416 may be removed. In
addition to the benefits of alignment between parts and additional
adhesive interfaces, the graduated radial gap may provide
additional benefits. For example, the adhesive 434, when disposed
between the bushing 416 and the pillow 412, may undergo certain
forces (such as capillary forces) that extract or purge air bubbles
from the adhesive 434. In this manner, the adhesive density of the
adhesive 434 increases and a stronger adhesive joint may be
achieved.
[0062] While the embodiment shown in FIG. 9 described a
bushing-pillow surface interface in which the gap distance
increases in a radially outward direction, other embodiments may
include different gap distance relationships. For example, in some
embodiments, the gap distances decrease in the radially outward
direction. Accordingly, in other embodiments, the first gap
distance 448 shown in FIG. 9 is greater than the second gap
distance 450, and the second gap distance 450 is greater than the
third gap distance 452, and so on. Further, in some embodiments, a
gap distance varies along a bushing-pillow surface interface. As an
example, in some embodiments, the first gap distance 448 varies
along an axial direction. In this manner, the first gap distance
448 may increase or decrease along the axial direction. This
described variance may be representative of a variance along
remaining bushing-pillow surface interfaces.
[0063] FIG. 10 illustrates an isometric view of the pillow 512, in
accordance with the described embodiments, showing various features
of the pillow 512. As shown, the pillow 512 includes an opening 506
and a flange feature 542. When the pillow 512 is formed from sheet
metal, the flange feature 542 may be formed by, for example, a
progressive die stamping operation. However, another metal bending
operation may be performed to form the flange feature 542, such as
deep drawing, MIM, die casting, machining (including a material
removal process), or the like. Also, although not shown, the pillow
512 may include a second flange feature proximate to the flange
feature 542. Also, while a discrete number of recessed portions,
such as the first recessed portion 524 and the second recessed
portion 526, are shown, the pillow 512 may include fewer or
additional recessed portion based in part on the number of stator
coils.
[0064] The exterior features of a fan assembly may include
additional enhancements. In particular, a pillow and a cover of a
fan assembly may include certain mating features designed to
improve assembly. For example, FIG. 11 illustrates a plan view of
an alternate embodiment of a fan assembly 600, in accordance with
the described embodiments. As shown, the fan assembly 600 includes
a pillow 612 and a cover 602 disposed over the pillow 612. In
embodiments when the cover 602 is metal, the cover 602 may be
formed from any means previously described for a pillow. However,
in other embodiments, the cover 602 is formed from a polymeric
material, such as plastic. Also, the pillow 612 may include a
flange feature 614 extending from the pillow 612. In some
embodiments, the flange feature 614 is integrally formed with the
pillow 612. The flange feature 614 includes an opening 616 designed
to receive a fastener or other object used to secure the pillow 612
with an additional feature. Also, while a single flange feature is
shown in FIG. 11, in other embodiments, the pillow 612 includes two
or more flange features.
[0065] FIG. 12 illustrates a partial isometric view of the fan
assembly show in FIG. 11 showing additional features of the pillow
612 and the cover 602. The cover 602 is separated from the pillow
612 to illustrate various features. For example, the cover 602 may
include a channel 604 designed to receive a flange portion 618 of
the pillow 612. The cover 602 may further include a chamfered
region 606 designed to accommodate the curved profile of the flange
portion 618 as shown in FIG. 12. Region 606 may also be a radius or
other shape instead of the chamfer shape shown. Although only a
partial view is shown, it should be understood that the channel 604
and the chamfered region 606 may extend along an outer perimeter of
the cover 602 in manner similar to what is shown in FIG. 12. Also,
the cover 602 may further include a second channel 608 designed to
receive the flange feature 614. Also, the cover 602 may include
additional channels similar to the second channel 608 to
accommodate any additional flange features of the pillow 612.
[0066] When the flange portion 618 is positioned in the channel
604, an adhesive may flow in a remaining void or space in the
channel 604. Further, the void or space may include optimal
dimensions to enhance an adhesive joint formed by the adhesive. For
example, FIG. 13 illustrates a cross sectional view of the fan
assembly 600 shown in FIGS. 11 and 12, further showing the pillow
612 adhesively secured with the cover 602. As shown, an adhesive
620 is disposed in the channel 604 of the cover 602 and extends
around the flange portion 618 of the pillow 612. The adhesive joint
formed by the adhesive 620 may exhibit several similar properties
previously described for an adhesive joint used to adhesively
secure a bushing with a pillow. For example, as shown in FIG. 13,
the adhesive 620 extends along multiple axial surfaces of the
flange portion 618, with an axial direction denoted by an arrow
630. Further, the adhesive 620 may include a first thickness
defined by a first gap thickness 622 between a first axial surface
of the flange portion 618 and a first surface of the channel 604.
The first gap thickness 622 may be a smaller thickness to assist in
aligning the cover 602 with the pillow. Further, the adhesive 620
may include a second thickness defined by a second gap thickness
624 between a radial surface of the flange portion 618 and a second
surface of the channel 604, with the second gap thickness 624 being
less than the first gap thickness 622. Also, the adhesive 620 may
include a third thickness defined by a third gap thickness 626
between a second axial surface of the flange portion 618 and a
second surface of the channel 604, with the third gap thickness 626
being less than the second gap thickness 624. Accordingly, the
adhesive 620, based upon the gap thicknesses, includes a thickness
(between surfaces) that may continually increases in a direction.
Further, the second gap thickness 624 may be adjusted in accordance
with the selected adhesive to ensure sufficient bond strength.
Accordingly, the adhesive 620 may include a graduated, or
increasing thickness. While FIG. 13 illustrates a side view, it
should be understood that the various features of the pillow 612,
such as the flange portion 618, extend around the pillow 612 in
location other than a flange feature (similar to the flange feature
614, shown in FIG. 12). Also, the channel 604 may extend around the
cover 602 in location corresponding to the flange portion 618.
Also, although not shown, the gap thicknesses may increase in the
opposite direction such that the first gap thickness 622 is less
than the second gap thickness 624, which in turn, is less than the
third gap thickness 626. Accordingly, in this described embodiment,
the adhesive 620, based upon the gap thicknesses, includes a
thickness that may continually increases in the opposite direction
as that shown in FIG. 13.
[0067] Also, the gap thicknesses may include a size and a shape to
create a desired effect with the adhesive 620. For example, the
space or void defined by the third gap distance 626, coupled with
the space or void between the channel 604 and curved region 628 of
the flange portion 618 (or curved region 628 of the pillow 612),
may combine to control an adhesive meniscus position to provide
cosmetic consistency to the fan assembly 600. As shown in FIG. 13,
the fan assembly 600 may include a first clearance 632 defined in
part by a first divergence rate between the first axial surface of
the channel 604 (which may include the chamfered region 606) and an
inner surface of the curved region 628 of the pillow 612. The first
clearance 632 may control certain dimensions (such as a size and a
shape) of a first meniscus 642 formed form the adhesive 620 during
a liquid (pre-cured) state of the adhesive 620 during assembly. In
addition, the fan assembly 600 may include a second clearance 634
defined in part by a second divergence between the second axial
surface of the channel 604 and an inner outer the curved region 628
of the pillow 612. The second clearance 634 may control certain
dimensions (such as a size and a shape) of a second meniscus 644
formed form the adhesive 620 during a liquid (pre-cured) state of
the adhesive 620 during assembly. In some embodiments, the first
clearance 632 (and, in turn, the first divergence rate) is similar
to the second clearance 634 (and, in turn, the second divergence
rate). In other embodiments, the first clearance 632 is different
than the second clearance 634. In either event, both the first
divergence rate and the second divergence rate can be adjusted by
adjusting the first clearance 632 and the second clearance 634,
respectively. Adjusting manufacturing parameters of the pillow 612
and/or the cover 602 can in turn adjust the first divergence and
the second divergence. By adjusting the first divergence, the first
meniscus 642 may be raised or lowered to a desired height in, for
example, a z-dimension. Also, by adjusting the second divergence,
the second meniscus 644 may be raised or lowered to a desired
height in, for example, a z-dimension. Accordingly, by adjusting
the menisci, the height of the adhesive 620 in the z-dimension can
be controlled to a desired height.
[0068] FIG. 14 illustrates an isometric view of an embodiment of a
fan assembly 700 that includes a stator 714 disposed on a pillow
712. The motor hub is removed for purposes of illustration. The
stator 714 may include several stator poles, each of which
including stator coils having electrically conductive wires wound
about the stator poles. For example, a first stator coil 718 and a
second stator coil 720 (adjacent to the first stator coil 718)
include electrically conductive wires wound around a first stator
pole 738 and a second stator pole 740 (adjacent to the first stator
pole 738), respectively. For purposes of clarity, the wire portions
interconnecting the stator coils are not shown. Also, the pillow
712 includes an opening 706 allowing a printed circuit assembly 728
to pass through pillow 712 and electrically connect to another
component (for example, a motor control circuit 319, in FIG. 4). In
some embodiments, the printed circuit assembly 728 is a printed
circuit board. In the embodiment shown in FIG. 14, the printed
circuit assembly 728 is a flexible printed circuit assembly.
[0069] One solution to positioning a terminating wire in a location
other than between a magnet and a printed circuit assembly is to
form several posts on the printed circuit assembly. For example,
FIG. 14 further illustrates the printed circuit assembly 728 having
several posts connected (electrically and mechanically) with the
printed circuit assembly 728. The posts may be positioned between
at least some of stator coils. For example, a first post 742
(representative of the remaining posts) is positioned between the
first stator coil 718 and the second stator coil 720 adjacent to
the first stator coil 718. As shown, the first post 742 is designed
to receive a wire portion 722 from the second stator coil 720, with
the wire portion 722 electrically connected with the first post
742. In this configuration, the stator coils may include a wire (of
a stator coil), which not only forms an electrical connection with
the printed circuit assembly 728 in a location between stator
coils, but also in a location other than between the printed
circuit assembly 728 and a motor hub when the motor hub is
installed. This allows for a clearance free of connections between
the motor hub and the printed circuit assembly 728 and a height of
the fan assembly 700 may be reduced.
[0070] Each post may also be referred to as a boss. Also, each post
may be mounted onto the printed circuit assembly 728 by, for
example, surface mount technology ("SMT"). Surface mount technology
may include an assembly process in which a circuit board (for
example, a printed circuit assembly 728) passes through a
"pick-and-place" machine designed to assemble the posts (such as
the first post 742) onto the circuit board. Also, in some
embodiments, the posts are formed from copper. In other
embodiments, the posts formed from brass. Generally, posts may be
formed from any electrically conductive material (or materials)
known in the art that may electrically connect with the printed
circuit assembly 728. As such, the posts may facilitate electrical
conduction from the wires of stator coils to the printed circuit
assembly 728, or vice versa. In any case, the posts may include a
metallic plating formed from a material such as tin in order to
facilitate the solderability needed for the wire connection (such
as the wire portion 722) to a first end of a post and the SMT
reflow process used to attach a second end of the post to the
printed circuit board. Also, in some embodiments, the posts may
include an insulated, non-electrically conductive material on an
exterior portion (e.g., curved lateral surface) in order to prevent
electrical shorting to adjacent stator coils such as the first
stator coil 718 or the second stator coil 720. For example, an
exterior portion 746 of the first post 742 is shown in FIG. 14.
Also, although not shown, each post in FIG. 14 may include a
pre-applied solder material designed to facilitate an electrically
connection between the wire portions and the posts.
[0071] The connection means for connection of a wire portion on the
posts may include conductive adhesive, soldering or other methods
for achieving electrical connection. Also, as shown in FIG. 14, the
posts may be elevated in order to facilitate the manufacturing
process. For example, the first post 742 is elevated relative to
the first stator coil 718 and the second stator coil 720, allowing
for tools, such as a soldering tool, to access the first post 742
without contacting the first stator coil 718 and/or the second
stator coil 720, thereby decreasing the likelihood of damage during
manufacturing and increasing the likelihood of improved
manufacturing times and throughput. Also, the posts may be
positioned between adjacent stator coils and may be centered
between the adjacent stator coils. By positioning posts between at
least some of the stator coils, the fan assembly 700 uses space
previously unoccupied. In this manner, the fan assembly 700 can
reduce its height in a dimension (such as a z-dimension) to reduce
the overall height of the fan assembly 700, and in turn, reduce an
overall height of an electronic device that includes the fan
assembly 700.
[0072] FIG. 15 illustrates an isometric view of an embodiment of a
printed circuit assembly 828 having several posts as well as an
elongated portion 830 designed to electrically connect with another
component. The printed circuit assembly 828 may be used with a fan
assembly previously described. However, several components (such as
a stator and stator coils) are removed for purposes of
illustration. In this regard, the elongated portion 830 may be
fitted with a connector (not shown) that terminates one or more
electrical connections of the printed circuit assembly 828 such
that the connector may electrically couple with another component.
Further, the elongated portion 830 may extend through an opening
(such as the opening 506 shown in FIG. 10) and the printed circuit
assembly 828 may be disposed on a pillow (such as the pillow 512
shown in FIG. 10).
[0073] In some embodiments, the printed circuit assembly 828 is a
flexible printed circuit assembly. As shown, the printed circuit
assembly 828 includes a first post 842, a second post 844, and a
third post 846. While the embodiment of the printed circuit
assembly 828 shows three posts, any number of posts necessary to
connect stator coil wires in a desired manner may be used. For
example, a 3-phase DC motor may require three posts, as shown.
However, other motors may include more or less posts. Also, the
printed circuit assembly 828 also includes extension in locations
proximate to the posts. For example, the printed circuit assembly
828 includes a first extension 852 proximate to first post 842. In
this manner, the first post 842, which includes electrically
conductive portions, does not contact any surface below the printed
circuit assembly 828 (for example, a pillow) thereby preventing, or
at least reducing, the probability of an electrical short. Also, as
shown the printed circuit assembly includes a second extension 854
and a third extension 856 to accommodate the second post 844 and
the third post 846, respectively.
[0074] Also, in some embodiments, the printed circuit assembly 828
is a ring, annulus, or other shape designed to accommodate various
components of a fan assembly. In the embodiment shown in FIG. 15,
the printed circuit assembly 828 is a U-shaped arc that includes a
first edge 864 and a second edge 866. The first edge 864 and/or the
second edge 866 may be shaped to conform to other structures
positioned on, or proximate to, a pillow (or other substrate). For
example, as shown FIG. 15, the first edge 864 and the second edge
866 combine to generally define a V-shaped configuration, which may
assist in aligning the printed circuit assembly 828, and in turn,
with a component having corresponding shape.
[0075] The bushing may include additional features designed to
facilitate connection of wires of a stator coil during an assembly
operation of a fan assembly. For example, FIG. 16 illustrates an
isometric view of an embodiment of a stator 914 surrounding a
bushing 916, in accordance with the described embodiments. In some
embodiments, the bushing 916 is formed from a non-electrically
conductive material (or materials) capable of withstanding heat in
order to facilitate certain operations, such as soldering. The
bushing 916 may include several protruding features having pins
formed from an electrically conductive material (or materials),
with the pins designed to receive a wire from a wire portion of the
stator coils. For example, as shown in FIG. 16, the bushing 916
includes a first protruding feature 942 integrally formed with the
bushing 916. In other words, the bushing 916 and the first
protruding feature 942 are formed as a single, continuous body from
the same material or materials. This may be performed by, for
example, an injection molding or a compression molding operation
having a mold cavity with a size and a shape of the bushing 916 and
one or more protruding features. Accordingly, the first protruding
feature 942 is formed from a non-electrically conductive material
(or materials). As shown, the first protruding feature 942 includes
a first pin 952 designed to receive a wire portion 922 from the
first stator coil 918. In some embodiments, the bushing 916 is
formed from a relatively less rigid material such that the first
protruding feature 942 is flexible with respect to the stator 914.
Also, the first stator coil 918, the first protruding feature 942,
and the first pin 952 may be representative of the remaining stator
coils, protruding features, and pins, respectively.
[0076] In some embodiments, the first pin 952 is an electrically
conductive feature that extends beyond the first protruding feature
942, allowing the wire portion 922 to be electrically connect with,
for example, a solder material. In the embodiment shown in FIG. 16,
the first pin 952 is a pogo-pin having spring-loaded pins designed
to receive the wire portion 922. Also, the first pin 952 extends
from a top portion of the first protruding feature 942 and further
extending from a bottom portion (not shown) of the first protruding
feature 942. In this manner, the first pin 952 may electrically
connect the first stator coil 918 with a printed circuit assembly
(not shown). Also, the first pin 952 may be electrically connected
to another component at the bottom portion (discussed below).
Similar to the posts shown in FIG. 15, the protruding features
shown in FIG. 16 are positioned between at least some of the stator
coils.
[0077] FIGS. 17 and 18 illustrate top and bottom views,
respectively, of the stator 914 and bushing 916, both of which are
shown in FIG. 16. However, the stator coils in FIG. 16 are removed
for purposes of illustration and clarity. FIG. 16 illustrates the
bushing 916 having a first protruding feature 942, a second
protruding feature 944, and third protruding feature 946, each of
which are centered between adjacent stator poles. The stator coils
wound around the stator poles are removed for purposes of clarity
and illustration. Also, the first pin 952 of the first protruding
feature 942 is designed to be elevated with respect to the stator
coils (not shown) in order to facilitate a wire connection
operation between the first pin 952 and a wire portion of a stator
coil. It will be appreciated that the first pin 952 is
representative of the remaining pins. Also, protruding features of
the bushing 916 may include one or more channel features that
provide functional enhancements similar to those of the channel 428
(shown in FIG. 8). For example, as shown in FIG. 17, the second
protruding feature 944 includes a channel 948. The channel 948 may
be designed to receive a flange feature (not shown) as well as an
adhesive to adhesively secure the bushing 916 with the flange
feature. Also, the channel 948 may be designed to form a gap region
with graduated gap distances in a manner previously described.
[0078] FIG. 18 illustrates a bottom view of the bushing 916,
showing the pins of the protruding features having an arch-shaped,
cantilevered bend. The cantilevered bend as well as the flexibility
of the protruding features act as a spring to create the "pogo
action" of the pogo pin, in those embodiments in which the pins are
pogo pins. For example, the first pin 952 is designed to provide a
preloading force to ensure electrical contact to a pad (not shown)
on a surface or region of another component (for example, a circuit
board or a connector of the keyboard 212 shown in FIG. 3) adjacent
to the fan of an electronic device 200 (shown in FIG. 3). The pins
may also include a connector integrated with the bushing 916. For
example, the first protruding feature 942 includes a first
connector 954 formed with the bushing 916. The first connector 954
is designed to receive the first pin 952, and may be representative
of the remaining connectors shown in FIG. 18. Also, the pins
extending from the bottom portion of bushing 916 indicate a
location in which the pins may exit a pillow of a fan assembly in
order to make an electrical connection with a contact pad (or pads)
located externally with respect to the fan assembly. This allows
the stator coils having wires connected with the pins to be
electrically connected to another component or components, such as
a motor control circuit 319 (shown in FIG. 3). Also, in this
manner, the stator coils need not be electrically connected to a
component via a printed circuit assembly (such as the printed
circuit assembly 828, shown in FIG. 16). Further, the bushing 916
may be formed from a non-electrically conductive material (or
materials). In this manner, the protruding features may form
electrically insulating features for at least a portion of their
respective pins.
[0079] To further illustrate, FIG. 19 illustrates a bottom view of
pillow 912 (or base) engaged with the bushing 916, with the pillow
912 having openings allowing the pins of a bushing 916 to extend
through the pillow 912 in order to electrically connect the stator
coils (not shown) with a component, such as a contact pad or
another printed circuit assembly. As shown, the first pin 952
(disposed in the first protruding feature 942, shown in FIG. 18)
extends through a first opening 964 of the pillow 912. When the
bushing 916 and the protruding feature are formed from
non-electrically conductive materials, the bushing 916 and the
protruding feature define an insulating sleeve around the first pin
952 to avoid electrical shorting to the pillow 912 when an
electrical current flows through the first pin 952. It will be
appreciated that the first pin 952 and its features are
representative of the remaining pins.
[0080] Although several means or locations for wire terminations
are disclosed, other means may be available. For example, in some
embodiments, individual male or female connectors are located
between the stator coils, and the electrical connection of the fan
assembly can be made through terminals of these connectors.
[0081] FIG. 20 illustrates a flowchart 1000 showing method for
reducing a dimension of a motor of a fan assembly of an electronic
device. In step 1002, several coils of the fan assembly are
positioned within a recessed portion of a pillow. In some
embodiments, the coils are stator coils of the fan assembly. In
some embodiments, the coils include a first stator coil and a
second stator coil, with first stator coil having a wire portion
capable of electrically connecting with a circuit assembly in a
location between the first stator coil and the second stator coil.
For example, a bushing may include several protruding features,
each of which may include a pin or other feature. Alternatively, a
circuit assembly may include several protrusions, each of which is
designed to receive a wire portion of the first stator coil and/or
the second stator coil.
[0082] In step 1004, the wire is terminated on a protrusion
positioned between the first stator coil and the second stator
coil. In some embodiments, the first stator coil is electrically
connected to a motor control circuit via the protrusion and a
printed circuit. In some embodiments, the protrusion is centered
between adjacent stator coils. In some embodiments, the protrusion
is electrically conductive. In other embodiments, the protrusion is
an assembly including a non-electrically conductive portion (e.g.,
nonconductive sleeve positioned on outer surface of the protrusion)
that is part of a non-electrically conductive stator bushing and an
electrically connecting portion. In this embodiment, the protrusion
(or protrusions) may include a pin configured to receive and
terminate the wire of the stator coil.
[0083] The various aspects, embodiments, implementations or
features of the described embodiments can be used separately or in
any combination. Various aspects of the described embodiments can
be implemented by software, hardware or a combination of hardware
and software. The described embodiments can also be embodied as
computer readable code on a computer readable medium for
controlling manufacturing operations or as computer readable code
on a computer readable medium for controlling a manufacturing line.
The computer readable medium is any data storage device that can
store data which can thereafter be read by a computer system.
Examples of the computer readable medium include read-only memory,
random-access memory, CD-ROMs, HDDs, DVDs, magnetic tape, and
optical data storage devices. The computer readable medium can also
be distributed over network-coupled computer systems so that the
computer readable code is stored and executed in a distributed
fashion.
[0084] The foregoing description, for purposes of explanation, used
specific nomenclature to provide a thorough understanding of the
described embodiments. However, it will be apparent to one skilled
in the art that the specific details are not required in order to
practice the described embodiments. Thus, the foregoing
descriptions of the specific embodiments described herein are
presented for purposes of illustration and description. They are
not targeted to be exhaustive or to limit the embodiments to the
precise forms disclosed. It will be apparent to one of ordinary
skill in the art that many modifications and variations are
possible in view of the above teachings.
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