Electrical motor using a heat spreader and cartridge control assembly
A motor assembly includes a housing having a motor cavity. A stator is disposed within the housing. A rotor rotates within the stator and within the motor cavity about a rotational axis. A controller is coupled with the stator having a filter circuit board and a main circuit board that are interconnected at a terminal header to define a multilayer circuit board assembly. The circuit board assembly has an electrical interface and a data interface attached to at least one of the filter circuit board and the main circuit board.
1. A motor assembly comprising:
a housing having a motor cavity;
a stator disposed within the housing;
a rotor that rotates within the stator and within the motor cavity about a rotational axis, the rotor attached to a fluid pump that directs a fluid from a fluid inlet of the housing and to a fluid outlet of the housing;
a controller coupled with the stator having a filter circuit board and a main circuit board that are interconnected at a terminal header to define a multilayer circuit board assembly, wherein the circuit board assembly has an electrical interface and a data interface attached to at least one of the filter circuit board and the main circuit board; and
a heat spreader that is attached to the housing, the heat spreader having a heat sink and a shaft that extends into the motor cavity along the rotational axis, wherein the heat sink draws heat from the circuit board assembly and transfers the heat to a thermal exchange media that is contained within the motor cavity, the thermal exchange media being recirculated through the motor cavity and the shaft of the heat spreader, and wherein the thermal exchange media is separated from the fluid moved by the fluid pump from the fluid inlet to the fluid outlet.
2. The motor assembly of claim 1 , wherein the shaft of the heat spreader is a hollow shaft through which the thermal exchange media is delivered from the circuit board assembly and through the motor cavity.
3. The motor assembly of claim 1 , wherein the controller is positioned within a controller cavity that is adjacent to the motor cavity.
4. The motor assembly of claim 3 , wherein the heat sink is an aluminum member that is disposed adjacent to the motor cavity and the controller cavity.
5. The motor assembly of claim 1 , wherein the thermal exchange media is glycol.
6. The motor assembly of claim 1 , further comprising a thermal gap interface material that is disposed between the heat sink and the main circuit board.
7. The motor assembly of claim 1 , wherein the main circuit board and the filter circuit board are interconnected at the terminal header to define the multilayer circuit board assembly.
8. The motor assembly of claim 1 , wherein the multilayer circuit board assembly is incorporated within a pre-assembled cartridge, and wherein the multilayer circuit board assembly includes electrical surface mounted technology (SMT) electrical sockets.
9. The motor assembly of claim 8 , wherein the SMT electrical sockets receive motor terminals of the stator, wherein the SMT electrical sockets place the motor terminals in electrical communication with the main circuit board.
10. The motor assembly of claim 1 , wherein the shaft of the heat spreader extends through the rotor and along the rotational axis of the rotor, and wherein a drive shaft of the rotor is disposed around the shaft of the heat spreader.
11. The motor assembly of claim 3 , wherein the heat spreader includes a base from which the shaft extends, and wherein the base includes a fluid slot through which the thermal exchange media travels between the controller cavity and the shaft.
12. A motor assembly comprising:
a wound stator that is overmolded to form a housing having a motor cavity within the stator;
a rotor that rotates within the motor cavity about a rotational axis; and
a controller having a filter circuit board and a main circuit board that are interconnected at a terminal header to define a multilayer circuit board assembly containing electrical surface mount technology electrical sockets for attaching motor terminals in electrical communication with the main circuit board, wherein the terminal header includes at least one insulator to limit electromagnetic communication between the filter circuit board and the main circuit board within areas outside of the terminal header, and wherein an electrical current delivered through the multilayer circuit board assembly is from approximately 10 amperes to approximately 50 amperes.
13. The motor assembly of claim 12 , wherein a connector for the controller includes electrical terminals that engage an upper socket that receives an upper portion of a blade for the connector and a lower socket that receives a lower portion of the blade.
14. The motor assembly of claim 13 , wherein the connector includes a first data interface that engages a first communications port of the filter circuit board, and wherein the connector includes a second data interface that engages a second communications port of the main circuit board.
15. The motor assembly of claim 12 , wherein the multilayer circuit board assembly is a pre-assembled cartridge that is attached to the housing and the wound stator.
16. A motor assembly comprising:
a wound stator that is overmolded to form a housing having a motor;
a rotor that rotates within a motor cavity about a rotational axis; and
a heat spreader that is attached to the housing, the heat spreader having a heat sink and a hollow shaft that extends into the motor cavity defining the rotational axis, wherein the heat sink draws heat from a circuit board assembly and transfers the heat to a thermal exchange media that is contained within the motor cavity and recirculated through the motor cavity and the hollow shaft.
17. The motor assembly of claim 16 , further comprising:
a controller coupled with the stator having a filter circuit board and a main circuit board that are interconnected at a terminal header to define the circuit board assembly, wherein the circuit board assembly has an electrical interface and at least one data interface that is attached to at least one of the filter circuit board and the main circuit board.
18. The motor assembly of claim 17 , wherein the controller is positioned within a controller cavity that is separated from and in thermal communication with the motor cavity.
19. The motor assembly of claim 1 , wherein the terminal header includes at least one insulator to limit electromagnetic communication between the filter circuit board and the main circuit board within areas outside of the terminal header, and wherein an electrical current delivered through the multilayer circuit board assembly is from approximately 10 amperes to approximately 50 amperes.
20. The motor assembly of claim 17 , wherein the terminal header includes at least one insulator to limit electromagnetic communication between the filter circuit board and the main circuit board within areas outside of the terminal header, and wherein an electrical current delivered through the circuit board assembly is from approximately 10 amperes to approximately 50 amperes.