Cooling components for motors

Abstract

The present invention describes a component (10) of an electric motor configured to cool a winding mounted therein, wherein the component is made of a material formed of an aggregate of particles coated with an electrically insulating layer, wherein the particles are substantially in contact with each other.

Description

Technical Field

[0001] The present invention generally relates to a cooling component for, for example, an electric motor mounted in an electric vehicle. As an example, this component can be advantageously applied, particularly to high-power motors in vehicles. Background Technology

[0002] High-power vehicles have motors with a rated power of several hundred kilowatts, so the primary requirement is cooling them. Summary of the Invention

[0003] The applicant has manufactured a motor stator capable of cooling windings mounted therein. The stator includes an outer ring, an inner ring concentric with the outer ring, and segments extending radially from the inner ring to the outer ring. These rings and segments are internally hollow and engage to form a continuous channel within them, capable of transporting cooling fluid along a path from one ring to another. The rings and segments are arranged to form or define through openings capable of accommodating and enclosing the assembly.

[0004] To achieve optimal performance, the stator must be able to be cooled very precisely, and its construction must prevent the generation of eddy currents within it.

[0005] The main objective of this invention is to improve upon existing technologies.

[0006] This objective is achieved by stator and / or components and / or methods as described in the appended claims, wherein the dependent claims define advantageous variations.

[0007] An electric motor component is proposed, which is configured to cool windings mounted therein, wherein the component is made of a material formed of an aggregate of particles coated with an electrically insulating layer and preferably embedded in an adhesive matrix.

[0008] These particles in the aggregate are preferably metallic. These particles in the aggregate are preferably in substantially contact with each other.

[0009] Specifically, a motor stator is proposed, which is configured to cool windings mounted therein, wherein, for example, the motor is mounted on an electric vehicle, the stator includes:

[0010] Outer ring road

[0011] The inner ring is concentric with the outer ring.

[0012] The section extending radially from the inner ring to the outer ring,

[0013] These rings and sections are hollow inside and join together to form continuous channels within them, which can transport cooling fluid along a path from one ring to another.

[0014] These rings and segments are arranged to form or define through openings that can accommodate and enclose the group.

[0015] The stator is made of a material that is formed from metal particles coated with an electrical insulating layer and preferably embedded in an adhesive matrix.

[0016] Due to this structure, the material acts as a good insulator for electric current, while also exhibiting good thermal conductivity given the proximity of the particles.

[0017] These particles can be made from the following materials: copper, aluminum or iron, magnesium oxide or boron nitride; diamond, silver, gold, laminated aluminum, brass, platinum, laminated steel, lead, and stainless steel. Generally, the materials used for the particles have a thermal conductivity λ [W·m]. -1 ·K -1 >15, more preferably λ[W·m -1 ·K -1 >100, or even better λ[W·m] -1 ·K -1 ]>300.

[0018] The insulating layer can be a layer made of oxide, insulating glaze, or aluminum oxide, and is usually a plastic or resin layer.

[0019] The adhesive matrix can be an adhesive, plastic, polymer, resin, or technopolymer. The adhesive matrix is ​​optional because strong pressure can bond the insulating film of each individual particle.

[0020] The metal particles may have a maximum diameter of, for example, 1 mm, more preferably 0.5 mm.

[0021] The relative percentage of metal particles in the matrix is ​​set such that most of the particles are in contact with each other or nearly in contact with each other, so that heat has a continuous path for propagation (a chain formed by particles that are attached or close together).

[0022] The stator allows fluid to circulate around the windings, which increases the heat absorption area. Furthermore, the continuous channels ensure a watertight seal, and water can be used as the fluid to utilize its high heat capacity.

[0023] Preferably, to simplify the structure, the outer ring and the inner ring define a circumference.

[0024] Preferably, to simplify the structure, the segment is a linear segment.

[0025] Preferably, to simplify the structure, the outer ring and the inner ring are located on essentially the same plane and are essentially coplanar.

[0026] Preferably, the outer ring, inner ring, and section are hollow shells.

[0027] Preferably, the continuous channel forms a path that rotates around the center of these rings for a full circle, allowing a large amount of heat to be dissipated from the windings.

[0028] Preferably, these segments extend radially along an axis passing through the center of these rings, and are particularly highly symmetrical with respect to that center. As a result, these segments form a hub-and-spoke configuration relative to these rings, which advantageously contacts the sides of the winding and carries away heat from those sides.

[0029] Preferably, there is one or more, particularly two, consecutive channels inside the stator. Multiple channels allow for faster and more balanced heat dissipation, preventing, for example, the fluid at the ends of the channels from becoming too hot and thus failing to effectively remove heat.

[0030] Conveniently, the modular stator is a consistent entity, for example, to facilitate assembly.

[0031] For each of the two or more stacked and insulated portions, a preferred configuration is that these portions form a separator for a single integral portion, the thickness of which is equal to the thickness of all the stacked rings.

[0032] Preferably, to maximize heat dissipation, the through opening has a profile complementary to the perimeter of the surrounding assembly. In particular, the surfaces of the inner edge of the outer ring and the outer edge of the inner ring include cusps, the tips of which are radially oriented and face the cusps of the opposite edges.

[0033] Another aspect of the invention relates to a method of manufacturing a component as defined above in one or each variant using the aggregate material, the component being particularly for the stator of an electric motor.

[0034] A variation of the method includes the steps of molding and / or compacting the material in a mold to obtain a part.

[0035] Another aspect of the invention relates to an electric motor equipped with a stator or component as defined above in one or each variant.

[0036] In particular, the present invention is preferably directed to the manufacture of a stator for an axial flux motor having a stator having a series of circular windings arranged around the rotational axis of the rotor, which generate magnetic flux with pole axes parallel to the rotational axis of the rotor. This type of motor has a more complex structure than a radial flux motor, but is lighter and smaller while maintaining the same power.

[0037] Therefore, an axial-flow motor is specifically proposed, which includes:

[0038] A rotor, capable of rotating about a rotation axis, equipped with a series of circular magnetic elements (e.g., permanent magnets).

[0039] The stator includes a series of circular bases to house a series of circular windings, each winding capable of generating a magnetic field with its polar axis parallel to the axis of rotation.

[0040] Each winding is configured to generate a magnetic field, which, through magnetic interaction with a series of circular magnetic elements of the rotor, causes the rotor to rotate.

[0041] The stator is manufactured as defined in one or each variant herein.

[0042] Another aspect of the invention relates to an electric vehicle equipped with a motor as defined above in one or each variant. Attached Figure Description

[0043] The advantages of the invention will become more apparent from the following description of a preferred embodiment of the stator, with reference to the accompanying drawings, wherein

[0044] · Figure 1 A three-dimensional view of the stator is shown. Detailed Implementation

[0045] Figure 1 The stator 10 of the motor is shown, which includes an outer circular ring 30, an inner circular ring 40 concentric with the outer ring 30, and straight sections or spokes 50 radially joining the two rings 30, 40. The outer ring 30 and the inner ring 40 are centered on the axis of rotation of the rotor (not shown).

[0046] Two adjacent segments 50 and the arched portions of the rings 30, 40 defined by them define a through cavity 36, which has a perimeter that is complementary to the windings mounted on the stator 10.

[0047] The number of sections or spokes 50 can be varied, thereby changing the number of windings.

[0048] Rings 30, 40 and section 50 are preferably hollow shells, and generally they form a continuous channel inside them to transport cooling fluid that enters the stator 10 from the inlet and exits from the outlet.

[0049] The fluid circulation within the stator 10 occurs along a path that involves at least two rings 30 and 40 and at least two sections 50. In other words, the fluid circulates within the stator 10, flowing from ring 30 through a section 50 to ring 40, and then from ring 40 through a different section 50 back to ring 30. During this flow, the fluid sweeps across the windings and carries away heat from them.

[0050] The number of channels for cooling fluid inside a component, especially the number of independent channels, can vary. Two or more separate channels can better dissipate heat from the windings, providing a more uniform operating temperature for the motor.

[0051] Stator 10 is made of a specific material, see [link / reference] Figure 1 Enlarged view in the image.

[0052] The material consists of compacted granules embedded in an adhesive 60. Each granule is formed from a metal core 62, which is coated with an electrically insulating layer or film 64.

[0053] The density of the particles in the adhesive 60 can be such that the distance between the particles is minimized, preferably all or almost all the particles are in contact with each other.

[0054] Therefore, due to the continuity provided by the metallic material that forms dense particles, the particle aggregates generally exhibit good thermal conductivity.

[0055] On the other hand, due to the insulating properties of layer 64, the particle aggregates behave as poor conductors of current.

[0056] Therefore, stator 10 can effectively remove the heat generated by the windings without incurring significant losses due to eddy currents.

Claims

1. A stator (10) of an electric motor, said stator being configured to cool windings mounted therein, said stator comprising: Outer ring (30), The inner ring (40) is concentric with the outer ring (30). The section (50) extending radially from the inner ring to the outer ring, The outer ring (30), inner ring (40), and section (50) are hollow inside and join together to form a continuous channel inside, which is capable of transporting cooling fluid along a path from one ring to another. The outer ring (30), inner ring (40), and section (50) are arranged to form or define a through opening that can receive and enclose the assembly. The stator (10) is characterized in that it is made of a material formed of an aggregate of particles coated with an electrically insulating layer (64), wherein the particles are substantially in contact with each other.

2. The stator (10) according to claim 1, wherein, The material constituting the particles has a thermal conductivity λ > 15 W·m -1 ·K -1 .

3. The stator (10) according to claim 1, wherein, The materials constituting the particles are selected from: copper, aluminum, iron, magnesium oxide, boron nitride, diamond, silver, gold, brass, platinum, lead, or stainless steel.

4. The stator (10) according to claim 1, wherein, The material constituting the particles is selected from laminated aluminum or laminated steel.

5. The stator (10) according to any one of claims 1-4, wherein, The insulating layer (64) is made of plastic.

6. The stator (10) according to any one of claims 1-4, wherein, The insulating layer (64) is resin.

7. The stator (10) according to any one of claims 1-4, wherein, The insulating layer is a layer composed of oxides.

8. The stator (10) according to any one of claims 1-4, wherein, The insulating layer is a layer composed of enamel.

9. The stator (10) according to any one of claims 1-4, wherein, The insulating layer is a layer composed of aluminum oxide.

10. The stator (10) according to any one of claims 1-4, wherein, The particles are embedded in the adhesive matrix (60).

11. The stator (10) according to claim 10, wherein, The adhesive matrix (60) is a polymer.

12. The stator (10) according to claim 10, wherein, The adhesive matrix (60) is an adhesive.

13. The stator (10) according to claim 10, wherein, The adhesive matrix (60) is plastic.

14. The stator (10) according to claim 10, wherein, The adhesive matrix (60) is a resin.

15. The stator (10) according to any one of claims 1-4, wherein, The particles have a maximum diameter of 1 mm.

16. The stator (10) according to any one of claims 1-4, wherein, The outer ring (30) and the inner ring (40) define a circumference.

17. The stator (10) according to any one of claims 1-4, wherein, The outer ring (30), inner ring (40) and section (50) are hollow shells.

18. The stator (10) according to any one of claims 1-4, wherein, The continuous channel forms a path that rotates around the center of the outer ring (30) and the inner ring (40) for a full circle.

19. The stator (10) according to any one of claims 1-4, wherein, The stator is a consistent entity.

20. The stator (10) according to any one of claims 1-4, wherein, The through opening has a profile that is complementary to the perimeter of the surrounding group.

21. The stator (10) according to any one of claims 1-4, wherein, The stator (10) is an axial flow motor. The stator (10) further includes a series of circular windings arranged around the rotation axis of the rotor to generate magnetic flux with a polar axis parallel to the rotation axis of the rotor. The rotor is equipped with permanent magnets for interacting with the generated magnetic field.

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