Linear motor with improved cooling

A linear motor comprising:

• a magnet plate having a plurality of magnets of alternating polarity affixed thereto;
• an armature block having at least one coil and a ceramic substrate heat sink;
• said at least one coil having a center aperture;
• said ceramic substrate heat sink having a plate surface and a protrusion extending from said plate surface and into said center aperture of said at least one coil positioned upon said plate surface;
• said at least one coil and said ceramic substrate heat sink being encapsulated in a settable resin;
• said armature block containing substantially no magnetic material;
• heat sink means for sinking heat carried by said ceramic substrate heat sink from said at least one coil;
• said heat sink means includes a cold plate affixed to a lower portion of said armature block;
• and
• said heat sink means includes means for allowing supply of a cooling liquid to said cold plate such that heat dissipated by said at least one coil in said armature block is removed by said cooling liquid.

A linear motor, comprising:

• a magnet plate having a plurality of magnets of alternating polarity affixed thereto;
• an armature block having at least one coil and a ceramic substrate heat sink;
• said at least one coil having a center aperture;
• said ceramic substrate heat sink having a plate surface and a protrusion extending from said plate surface and into said center aperture of said at least one coil positioned upon said plate surface;
• said at least one coil and said ceramic substrate heat sink being encapsulated in a settable resin;
• said armature block containing substantially no magnetic material;
• heat sink means for sinking heat carried by said ceramic substrate heat sink from said at least one coil;
• said heat sink means includes a cold plate affixed to a lower portion of said armature block;
• and
• said heat sink means includes means for allowing supply of a cooling liquid to said cold plate such that heat dissipated by said at least one coil in said armature block is removed by said cooling liquid;
• said ceramic substrate heat sink includes a base portion;
• said base portion is affixed in said cold plate;
• and
• said base portion has a thickness greater than said ceramic substrate heat sink at said plate surface so as to decrease a thermal junction resistance between said base portion and said cold plate.

A linear motor comprising:

• a magnet plate having a plurality of magnets of alternating polarity affixed thereto;
• an armature block having at least one coil and a ceramic substrate heat sink;
• said ceramic substrate heat sink being located on a side of said armature block;
• said ceramic substrate heat sink having a recess for accepting said at least one coil;
• said at least one coil and said ceramic substrate heat sink being encapsulated in a settable resin;
• said armature block containing substantially no magnetic material;
• heat sink means for sinking heat carried by said ceramic substrate heat sink from said at least one coil;
• and
• said ceramic substrate heat sink contacting at least a portion of said heat sink means, whereby heat is effectively removed from a middle portion of said armature block.

A linear motor comprising:

• a U-frame having opposing inner walls, joined by a bridge portion at a closed end, defining a longitudinal cavity;
• said opposing inner walls having a plurality of magnets of alternating polarity affixed thereto;
• an armature block having at least one coil encapsulated in a settable resin and traveling within said U-frame;
• said armature block containing substantially no magnetic material;
• said U-frame having a duct extending throughout a longitudinal length thereof;
• said duct having orifices connecting said duct with said longitudinal cavity;
• said duct and said orifices permitting cooling air to be introduced into said longitudinal cavity such that heat generated in said armature block is removed by said cooling air;
• a cold plate affixed to a bottom portion of said armature block;
• a ceramic heat sink plate affixed to a side of said armature block and in thermal contact with said cold plate, such that heat is effectively removed from a middle portion of said armature block;
• means for allowing supply of a cooling liquid to said cold plate such that heat dissipated by said at least one coil in said armature block is removed by said cooling liquid;
• and
• said orifices directing a flow of cooling air at a top portion of said armature block furthest from said first cold plate.

A method of making a linear motor, comprising the steps of:

• positioning a frame with permanent magnets adjacent an armature element having electrical coils and a duct in such a way as to form a space between said frame and said armature element;
• forming a passage in said armature passing from one surface of said armature not adjacent said space through said duct and into said space thereby forming a passage opening to said space at a first opening of said passage and opening through said one surface not adjacent said space at a second opening of said passage;
• sealing said second opening so that said duct communicates with said space without leaking through said second opening;
• injecting air into said space through said duct, through said passage and out through said first opening.