Abstract:
A method for assembling a heat-dissipating module includes a step of mechanically pressing one time or multiple times a heat pipe into a trough of a metallic base, whereby at least one end of the heat pipe can be pressed into the trough of the metallic base and thus firmly combined with the metallic base. In this way, the time and the cost for assembly are reduced, and the yield is increased.

Description:
[0001]    This application claims the priority benefit of Taiwan patent application number 100102805 filed on Jan. 26, 2011. 
       FIELD OF THE INVENTION 
       [0002]    The present invention relates to a motor water-cooling structure and a manufacturing method thereof; and more particularly to a motor water-cooling structure that includes a motor case formed of one or more types of materials, and a tube embedded in the motor case to serve as a water passage, so as to reduce the manufacturing cost and avoid the risk of water leakage. 
       BACKGROUND OF THE INVENTION 
       [0003]    A motor is a prerequisite machine for energy conversion. There are motors that convert electric energy into kinetic energy, such as the motors for fans, water pumps and the like. There are also motors that convert kinetic energy into electric energy, such as power generators. Most of the currently available motors are used for the above-mentioned applications. Either the motors for converting electric energy into kinetic energy or the motors for converting kinetic energy into electric energy, they all include stators or rotors that would produce heat during operation thereof. When the produced heat is too high or largely accumulated in the motor, it would have adverse influence on the working efficiency of the motor. In some worse conditions, the motor might become burnt out due to excessive heat produced by the stator or the rotor and accumulated in the motor. 
         [0004]    In some conventional ways for overcoming the above problem, holes are formed on a motor case to allow convection of air inside and outside the motor case, so that the heat produced by the motor during operation thereof is dissipated via air cooling. However, air cooling appears to have only limited effect in removing the produced heat from the motor. And, foreign matters, moisture and solutions tend to invasion into an interior of the motor via the holes formed on the motor case to cause damage to the stator and the rotor. Therefore, it is necessary to improve the conventional air cooling structure for motors. 
         [0005]    There are also manufacturers who try to remove the internally produced heat from the motor by water cooling. To do so, a groove is formed on an outer side of a motor case to spirally extend in an axial direction of the motor case, and an enclosure is provided to cover the outer side of the motor case and the groove formed thereon, so that the groove forms a water passage in between the motor case and the enclosure. While the water cooling largely improves the heat dissipation of the motor, it also brings other problems to the motor. That is, in the case the motor case and the enclosure are fabricated with insufficient precision, or in the event the material for forming the motor case and the enclosure become oxidized or corroded, cooling water flowing through the water passage tends to leak out of the groove. Further, the forming of the groove on the motor case and the production of the enclosure with highly accurate dimensions are complicated and time consuming to inevitably increase the manufacturing cost of the motor. 
         [0006]    In brief, the conventional water-cooling structure for motors has the following disadvantages: (1) requiring complicated fabricating processes; (2) requiring relatively high manufacturing costs; and (3) being subject to water leakage. 
       SUMMARY OF THE INVENTION 
       [0007]    A primary object of the present invention is to provide a motor water-cooling structure capable of preventing leakage of water therefrom. 
         [0008]    Another object of the present invention is to provide a method of manufacturing motor water-cooling structure that enables reduced manufacturing cost of a motor water-cooling structure. 
         [0009]    To achieve the above and other objects, the motor water-cooling structure according to the present invention includes a motor case having a wall portion and a tube. The wall portion has an inner side and an outer side, and the tube has an outlet, an inlet, and a tube body. The tube body is embedded in the motor case while the outlet and the inlet are exposed from the outer side of the motor case. 
         [0010]    To achieve the above and other objects, the method of manufacturing motor water-cooling structure according to an embodiment of the present invention includes the following steps: 
         [0011]    providing a mold having a mold cavity and a tube; and 
         [0012]    positioning the tube in the mold cavity of the mold, and forming a motor case in the mold by pour molding to embed the tube in the motor case. 
         [0013]    To achieve the above and other objects, the method of manufacturing motor water-cooling structure according to another embodiment of the present invention includes the following steps: 
         [0014]    providing a mold having a mold cavity, a first motor case, and a tube; and 
         [0015]    winding the tube around an outer side of the first motor case; positioning the first motor case having the tube wound therearound in the mold cavity of the mold; and forming a second motor case on the outer side of the first motor case to cover the first motor case and the tube, so that the second motor case, the first motor case, and the tube form an integral body. 
         [0016]    To achieve the above and other objects, the method of manufacturing motor water-cooling structure according to a further embodiment of the present invention includes the following steps: 
         [0017]    providing a mold having a mold cavity, a first motor case having a groove provided on an outer side thereof, and a tube; and 
         [0018]    setting the tube in the groove on the outer side of the first motor case, positioning the first motor case having the tube set in the groove in the mold cavity of the mold, and forming a second motor case on the outer side of the first motor case to cover the first motor case and the tube, so that the second motor case, the first motor case and the tube form an integral body. 
         [0019]    With the present invention, the motor case for the motor water-cooling structure can be formed with one or more types of materials and the tube embedded in the motor case may can serve as a water passage, enabling the motor water-cooling structure to be manufactured at reduced material, labor and time costs, and to avoid the risk of water leakage. Therefore, the present invention has the following advantages: (1) saving the manufacturing cost; and (2) avoiding the risk of water leakage. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0020]    The structure and the technical means adopted by the present invention to achieve the above and other objects can be best understood by referring to the following detailed description of the preferred embodiments and the accompanying drawings, wherein 
           [0021]      FIG. 1  is a perspective view of a motor water-cooling structure of the present invention according to a first embodiment thereof; 
           [0022]      FIG. 2  is a sectioned perspective view of the motor water-cooling structure of  FIG. 1 ; 
           [0023]      FIG. 3  is a perspective view of a motor water-cooling structure of the present invention according to a second embodiment thereof; 
           [0024]      FIG. 3   a  is a sectioned perspective view of the motor water-cooling structure of  FIG. 3 ; 
           [0025]      FIG. 4  is a sectioned perspective view of a motor water-cooling structure of the present invention according to a third embodiment thereof; 
           [0026]      FIG. 4   a  is a sectioned perspective view of a first part of a wall portion of the motor water-cooling structure of  FIG. 4 ; 
           [0027]      FIG. 5  is a flowchart showing the steps included in a first embodiment of a method of manufacturing a motor water-cooling structure according to the present invention; 
           [0028]      FIGS. 6 and 7  illustrate the manufacturing method of the present invention according to the first embodiment thereof; 
           [0029]      FIGS. 8 and 9  illustrate the manufacturing method of the present invention according to a second embodiment thereof; 
           [0030]      FIG. 10  is a flowchart showing the steps included in a third embodiment of the method of manufacturing a motor water-cooling structure according to the present invention; 
           [0031]      FIGS. 11 and 12  illustrate the manufacturing method of the present invention according to the third embodiment thereof; 
           [0032]      FIGS. 13 and 14  illustrate the manufacturing method of the present invention according to a fourth embodiment thereof; 
           [0033]      FIG. 15  is a flowchart showing the steps included in a fifth embodiment of the method of manufacturing a motor water-cooling structure according to the present invention; 
           [0034]      FIGS. 16 and 17  illustrate the manufacturing method of the present invention according to the fifth embodiment thereof; and 
           [0035]      FIGS. 18 and 19  illustrate the manufacturing method of the present invention according to a sixth embodiment thereof. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0036]    The present invention will now be described with some preferred embodiments thereof and with reference to the accompanying drawings. For the purpose of easy to understand, elements that are the same in the preferred embodiments are denoted by the same reference numerals. 
         [0037]    Please refer to  FIGS. 1 and 2  that are perspective and sectioned perspective views, respectively, of a motor water-cooling structure of the present invention according to a first embodiment thereof. As shown, the motor water-cooling structure in the first embodiment includes a motor case  11  having a wall portion  111  and a tube  112 . The wall portion  111  has an inner side  1111  and an outer side  1112 . The tube  112  has an outlet  1121 , an inlet  1122 , and a tube body  1123 . The tube body  1123  is embedded in the wall portion  111  while the outlet  1121  and the inlet  1122  are exposed from the outer side  1112  of the wall portion  111 . 
         [0038]    Please refer to  FIGS. 3 and 3   a  that are perspective and sectioned perspective views, respectively, of the motor water-cooling structure of the present invention according to a second embodiment thereof. As shown, the motor water-cooling structure in the second embodiment is generally structurally similar to the first embodiment, except that the wall portion  111  in the second embodiment includes a first part  111   a  and a second part  111   b  located outside the first part  111   a , as well as the tube  112 . 
         [0039]    The first part  111   a  and the second part  111   b  are in contact with and connected to each other with the tube body  1123  of the tube  112  embedded in between the first part  111   a  and the second part  111   b  of the wall portion  111 . And, the outlet  1121  and the inlet  1122  of the tube  112  are exposed from an outer side of the second part  111   b.    
         [0040]    Please refer to  FIGS. 4 and 4   a .  FIG. 4  is a sectioned perspective view of the motor water-cooling structure of the present invention according to a third embodiment thereof; and  FIG. 4   a  is a sectioned perspective view of a first part of the wall portion of the motor water-cooling structure of  FIG. 4 . As shown, the motor water-cooling structure in the third embodiment is generally structurally similar to the second embodiment, except that the first part  111   a  of the wall portion  111  in the third embodiment is formed on an outer side facing toward the second part  111   b  with at least one groove  111   c , which is spirally extended in an axial direction of the first part  111   a  of the wall portion  111  with the tube  112  set therein. When the second part  111   b  and the first part  111   a  of the wall portion  111  are connected to each other, the tube  112  set in the groove  111   c  is sandwiched between the first and the second part  111   a ,  111   b.    
         [0041]    In the above-described second and third embodiments, the first part  111   a  and the second part  111   b  of the wall portion  111  as well as the tube  112  can be made of a metal material or a non-metal material. In the case of a metal material, the material can be any one of a copper material, an aluminum material, a stainless steel material, and any other metal materials. And, in the case of a non-metal material, the material can be a plastic material. 
         [0042]      FIG. 5  is a flowchart showing the steps included in a first embodiment of a method according to the present invention for manufacturing a motor water-cooling structure; and  FIGS. 6 and 7  illustrate the manufacturing method in the first embodiment thereof. Please refer to  FIGS. 5 ,  6  and  7  along with  FIGS. 1 and 2 . 
         [0043]    In a first step S 1  according to the first embodiment of the manufacturing method, a mold having a mold cavity and a tube are provided. 
         [0044]    More specifically, as can be seen from  FIGS. 6 and 7 , a mold  2  having a mold cavity  21  is provided. The mold cavity  21  is dimensioned corresponding to a motor case that is to be formed, such as the motor case  11  shown in  FIGS. 1 and 2 . And, a tube, such as the tube  112  shown in  FIGS. 1 and 2 , is also provided. 
         [0045]    Then, in a second step S 2 , the tube is positioned in the mold cavity of the mold, and a motor case is formed by pour molding to embed the tube therein. 
         [0046]    More specifically, as can be seen from  FIGS. 6 and 7 , the tube  112  is positioned in the mold cavity  21  of the mold  2 , and a motor case, e.g. the motor case  11 , is formed by injection molding a plastic material or a metal material in the mold  2 , so that the tube  112  is embedded in the motor case (e.g. the motor case  11 ) to serve as a flow passage in the molded motor case  11 . 
         [0047]      FIG. 5  also shows the steps included in a second embodiment of the method according to the present invention for manufacturing a motor water-cooling structure; and  FIGS. 8 and 9  illustrate the manufacturing method in the second embodiment thereof. Please refer to  FIGS. 5 ,  8  and  9  along with  FIGS. 1 and 2 . 
         [0048]    A first step S 1  according to the second embodiment of the manufacturing method is the same as that in the first embodiment and is therefore not repeatedly described. 
         [0049]    Then, in a second step S 2 , which is different from that in the first embodiment, the tube is positioned in the mold cavity of the mold, and a motor case is formed by pour molding to embed the tube therein. 
         [0050]    More specifically, as can be seen from  FIGS. 8 and 9 , the tube  112  is positioned in a mold cavity  31  of a casting mold  3 , and a motor case, e.g. the case  11 , is cast by pouring a molten metal material  4  into the mold cavity  31  of the casting mold  3 , so that the tube  112  is embedded in the cast motor case (e.g. the motor case  11 ) to serve as a flow passage in the cast motor case  11 . 
         [0051]      FIG. 10  is a flowchart showing the steps included in a third embodiment of the method according to the present invention for manufacturing a motor water-cooling structure; and  FIGS. 11 and 12  illustrate the manufacturing method in the third embodiment thereof. Please refer to  FIGS. 10 ,  11  and  12  along with  FIGS. 3 and 3   a.    
         [0052]    In a first step X 1  according to the third embodiment of the manufacturing method, a mold having a mold cavity, a first motor case, and a tube are provided. 
         [0053]    More specifically, as can be seen from  FIGS. 11 and 12 , a mold  2  having a mold cavity  21  is provided. And, a first motor case, such as the first part  111   a  shown in  FIGS. 3 and 3   a , and a tube, such as the tube  112  shown in  FIGS. 3 and 3   a , are also provided. 
         [0054]    Then, in a second step X 2 , the tube is wound around an outer side of the first motor case, and the first motor case with the tube wound therearound is positioned in the mold cavity of the mold; and a second motor case is formed on an outer side of the first motor case to cover the first motor case and the tube, so that the second motor case, the first motor case and the tube form an integral body. 
         [0055]    More specifically, as can be seen from  FIGS. 11 and 12 , the tube  112  is wound around the outer side of the first motor case (e.g. the first part  111   a ), and the first motor case with the tube  112  wound therearound is positioned in the mold cavity  21  of the mold  2 ; and a second motor case, e.g. the second part  111   b  shown in  FIGS. 3 and 3   a , is formed on an outer side of the first motor case (e.g. the first part  111   a ) by injection molding a plastic material or a metal material in the mold  2  to cover the first motor case (e.g. the first part  111   a ) and the tube  112 , so that the second motor case (e.g. the second part  111   b ), the first motor case (e.g. the first part  111   a ), and the tube (e.g. the tube  112 ) form an integral body. 
         [0056]      FIG. 10  also shows the steps included in a fourth embodiment of the method according to the present invention for manufacturing a motor water-cooling structure; and  FIGS. 13 and 14  illustrate the manufacturing method in the fourth embodiment thereof. Please refer to  FIGS. 10 ,  13  and  14  along with  FIGS. 3 and 3   a.    
         [0057]    A first step X 1  according to the fourth embodiment of the manufacturing method is the same as that in the third embodiment and is therefore not repeatedly described. 
         [0058]    Then, in a second step X 2 , which is different from that in the third embodiment, the tube is wound around an outer side of the first motor case, and the first motor case with the tube wound therearound is positioned in the mold cavity of the mold; and a second motor case is formed on an outer side of the first motor case to cover the first motor case and the tube, so that the second motor case, the motor case and the tube form an integral body. 
         [0059]    More specifically, as can be seen from  FIGS. 13 and 14 , the tube (e.g. the tube  112 ) is wound around the outer side of the first motor case (e.g. the first part  111   a ), and the first motor case (e.g. the first part  111   a ) with the tube (e.g. the tube  112 ) wound therearound is positioned in a mold cavity  31  of a casting mold  3 ; and a second motor case, e.g. the second part  111   b  shown in  FIGS. 3 and 3   a , is cast by pouring a molten metal material  4  into the mold cavity  31  of the casting mold  3  to cover the first motor case (e.g. the first part  111   a ) and the tube (e.g. the tube  112 ), so that the second motor case (e.g. the second part  111   b ), the first motor case (e.g. the first part  111   a ) and the tube (e.g. the tube  112 ) form an integral body with the tube (e.g. the tube  112 ) forming a flow passage in between the first motor case (e.g. the first part  111   a ) and the second motor case (e.g. the second part  111   b ). 
         [0060]      FIG. 15  is a flowchart showing the steps included in a fifth embodiment of the method according to the present invention for manufacturing a motor water-cooling structure; and  FIGS. 16 and 17  illustrate the manufacturing method in the fifth embodiment thereof. Please refer to  FIGS. 15 ,  16  and  17  along with  FIGS. 4 and 4   a.    
         [0061]    In a first step Y 1  according to the fifth embodiment of the manufacturing method, a mold having a mold cavity, a first motor case having a groove provided on an outer side thereof, and a tube are provided. 
         [0062]    More specifically, as can be seen from  FIGS. 16 and 17 , a mold  2  having a mold cavity  21  is provided. And, a first motor case, such as the first part  111   a  shown in  FIGS. 4 and 4   a , having a groove (e.g. the groove  111   c ) provided on an outer side thereof, and a tube, such as the tube  112  shown in  FIGS. 4 and 4   a , are also provided. 
         [0063]    Then, in a second step Y 2 , the tube is set in the groove on the outer side of the first motor case, and the first motor case with the tube set in the groove is positioned in the mold cavity of the mold; and a second motor case is formed on an outer side of the first motor case to cover the first motor case and the tube, so that the second motor case, the first motor case and the tube form an integral body. 
         [0064]    More specifically, as can be seen from  FIGS. 16 and 17 , the tube (e.g. the tube  112 ) is set in the groove (e.g. the groove  111   c ) formed on the outer side of the first motor case (e.g. the first part  111   a ), and the first motor case (e.g. the first part  111   a ) with the tube (e.g. the tube  112 ) set in the groove is positioned in the mold cavity  21  of the mold  2 ; and a second motor case, e.g. the second part  111   b  shown in  FIGS. 4 and 4   a , is formed on an outer side of the first motor case (e.g. the first part  111   a ) by injection molding a plastic material or a metal material in the mold  2  to cover the first motor case (e.g. the first part  111   a ) and the tube (e.g. the tube  112 ), so that the second motor case (e.g. the second part  111   b ), the first motor case (e.g. the first part  111   a ) and the tube (e.g. the tube  112 ) form an integral body. 
         [0065]      FIG. 15  also shows the steps included in a sixth embodiment of the method according to the present invention for manufacturing a motor water-cooling structure; and  FIGS. 18 and 19  illustrate the manufacturing method in the sixth embodiment thereof. Please refer to  FIGS. 15 ,  18  and  19  along with  FIGS. 4 and 4   a.    
         [0066]    A first step Y 1  according to the sixth embodiment of the manufacturing method is the same as that in the fifth embodiment and is therefore not repeatedly described. 
         [0067]    Then, in a second step Y 2 , which is different from that in the fifth embodiment, the tube is set in the groove formed on the outer side of the first motor case, and the first motor case with the tube set in the groove is positioned in the mold cavity of the mold; and a second motor case is formed on an outer side of the first motor case to cover the first motor case and the tube, so that the second motor case, the first motor case and the tube form an integral body. 
         [0068]    More specifically, as can be seen from  FIGS. 18 and 19 , the tube (e.g. the tube  112 ) is set in the groove (e.g. the groove  111   c ) formed on the outer side of the first motor case (e.g. the first part  111   a ), and the first motor case (e.g. the first part  111   a ) with the tube (e.g. the tube  112 ) set in the groove is positioned in a mold cavity  31  of a casting mold  3 ; and a second motor case, e.g. the second part  111   b  shown in  FIGS. 4 and 4   a , is cast by pouring a molten metal material  4  into the mold cavity  31  of the casting mold  3  to cover the first motor case (e.g. the first part  111   a ) and the tube (e.g. the tube  112 ), so that the second motor case (e.g. the second part  111   b ), the first motor case (e.g. the first part  111   a ) and the tube (e.g. the tube  112 ) form an integral body with the tube (e.g. the tube  112 ) forming a flow passage in between the first motor case (e.g. the first part  111   a ) and the second motor case (e.g. the second part  111   b ). 
         [0069]    With the first to the sixth embodiment of the method according to the present invention for manufacturing a motor water-cooling structure, the motor water-cooling structure can be formed with one or more types of materials at reduced material, labor and time costs. Further, a material with relatively high thermal conductivity, such as a copper material, and a material with relatively high heat dissipation efficiency, such as an aluminum material, can be selected for forming the first part and the second part of the motor case, respectively, to embed the tube  112  therebetween by means of insert molding, so as to achieve the object of upgrading the heat dissipation efficiency of the motor water-cooling structure. 
         [0070]    Moreover, the use of the tube  112  to replace the water passages for the conventional motor water-cooling structure can not only prevent the risk of water leakage, but also save the time and labor for mechanically forming the water passages on the motor case, and accordingly, enables increased good yield and reduced manufacturing cost of motor water-cooling structure. 
         [0071]    The present invention has been described with some preferred embodiments thereof and it is understood that many changes and modifications in the described embodiments can be carried out without departing from the scope and the spirit of the invention that is intended to be limited only by the appended claims.