Water-cooled stator structure of axial flux motor

Abstract

The invention provides a water-cooling stator structure of an axial flux motor. The stator comprises a stator body, a cooling water pipeline, an inner communication water channel structure, an outer communication water channel structure and a thermosetting insulating material. The plurality of conductor wires pass through the plurality of slots of the stator body along the radial direction to form a distributed winding. The plurality of cooling water pipes are made of waterproof non-magnetic materials, penetrate through the stator body in the radial direction and are located between the inner space and the outer diameter side wall. The inner communicating water channel structure and the outer communicating water channel structure communicate with the two sides of the multiple cooling water pipelines. And the thermosetting insulating material is filled among the plurality of inner diameter protruding parts, the plurality of outer diameter protruding parts, the inner communication water channel structure and the outer communication water channel structure.

Description

TECHNICAL FIELD

[0001] The present invention relates to a water-cooled stator structure, and more particularly to a water-cooled stator structure of an axial flux motor. BACKGROUND

[0002] A known stator is composed of two annular plates and two cylindrical walls to form a cylindrical housing, coils are arranged in the housing, and the housing is provided with an inlet and an outlet for cooling liquid, wherein the cooling liquid flows back and forth between the inner and outer diameters through the gaps between the coils.

[0003] One of the disadvantages of the known stator is that it can only be applied to a concentrated winding stator, and a distributed winding stator does not have gaps between the windings, so it cannot use this cooling method. The second disadvantage of the known stator is that the cooling liquid directly contacts the windings. If water-containing or conductive cooling liquid is used, it may not only directly cause short circuit between the conductors, but also have a negative impact on the insulation material contacted, resulting in damage to the insulation. SUMMARY

[0004] The purpose of the present invention is to provide a water-cooled stator structure of an axial flux motor to solve the problems of the prior art.

[0005] According to some embodiments of the present invention, a water-cooled stator structure of an axial flux motor comprises: a hollow annular stator body having a plurality of slot positions; a plurality of conductor wires radially passing through the plurality of slot positions to form a distributed winding structure, and having a plurality of inner diameter protrusions and a plurality of outer diameter protrusions, the plurality of inner diameter protrusions being located in an internal space of the stator body, and the plurality of outer diameter protrusions being exposed outside the outer diameter side wall of the stator body; a plurality of cooling water pipes made of a waterproof non-magnetic material, radially passing through the stator body, and connecting between the internal space and the outer diameter side wall; an internal communication water channel structure communicating with the plurality of cooling water pipes, and having an internal water-tight structure contacting one end of the plurality of cooling water pipes; an external communication water channel structure communicating with the plurality of cooling water pipes, and having an external water-tight structure contacting the other end of the plurality of cooling water pipes; and a thermosetting insulating material filled between the plurality of inner diameter protrusions, the plurality of outer diameter protrusions, the internal communication water channel structure, and the external communication water channel structure.

[0006] According to some embodiments of the present invention, the stator body is a soft magnetic material body, and the plurality of cooling water pipes are arranged in a radial manner and pass through the stator body.

[0007] According to some embodiments of the present invention, the internal communication water channel structure comprises an inner upper annular ring and an inner lower annular ring to form a plurality of internal communication water channels arranged in a radial manner to respectively communicate with the plurality of ends of the plurality of cooling water pipes.

[0008] According to some embodiments of the present invention, the internal water-tight structure is located between the stator body and the internal communication water channel structure.

[0009] According to some embodiments of the present application, the inner water-tight structure comprises an elastic polymer material or a gel material.

[0010] According to some embodiments of the present application, the outer communicating water channel structure comprises an outer upper circular ring and an outer lower circular ring to form a plurality of outer communicating water channels in a radial arrangement to respectively communicate with the other ends of the plurality of cooling water pipes.

[0011] According to some embodiments of the present application, the outer water-tight structure is located between the stator body and the outer communicating water channel structure.

[0012] According to some embodiments of the present application, the outer water-tight structure comprises an elastic polymer material or a gel material.

[0013] According to some embodiments of the present application, the inner communicating water channel structure comprises a plurality of conical protrusions arranged in a circular ring.

[0014] According to some embodiments of the present application, each of the conical protrusions is located between two adjacent inner radial protrusions.

[0015] According to some embodiments of the present application, the water-cooled stator structure further comprises an inner cooling water channel structure located in the inner space of the stator body, wherein the plurality of inner radial protrusions are located between the stator body and the inner cooling water channel structure; and an outer cooling water channel structure surrounding the outer radial sidewall of the stator body, wherein the plurality of outer radial protrusions are located between the stator body and the outer cooling water channel structure.

[0016] According to some embodiments of the present application, the water-cooled stator structure further comprises a thermosetting insulating material filled between the stator body, the outer cooling water channel structure, and the plurality of outer radial protrusions.

[0017] According to some embodiments of the present application, the water-cooled stator structure further comprises a thermosetting insulating material filled between the stator body, the inner cooling water channel structure, and the plurality of inner radial protrusions.

[0018] According to some embodiments of the present application, the inner cooling water channel structure comprises two inner ring water channel walls abutting each other to form an inner cooling water channel between the two inner ring water channel walls.

[0019] According to some embodiments of the present application, the inner ring water channel wall close to the stator body has a plurality of concave-convex features, and the thermosetting insulating material is filled between the stator body, the plurality of inner radial protrusions, the inner ring water channel wall, and the plurality of concave-convex features.

[0020] According to some embodiments of the present application, the outer cooling water channel structure comprises two outer ring water channel walls abutting each other to form an outer cooling water channel between the two outer ring water channel walls.

[0021] In summary, the water-cooled stator structure of the axial flux motor of the present application uses a non-magnetic material that prevents water penetration as a cooling water pipe to connect the inner and outer cooling water channels of the stator body, so that the cooling water can directly enter the stator interior with high heat generation density for heat exchange. The cooling water pipe penetrates the soft magnetic material of the stator and effectively prevents the cooling water inside from leaking out or directly contacting the soft magnetic material. The inner and outer cooling water channel structures and the conductor wire (inner diameter protruding part or outer diameter protruding part) are filled with a thermosetting insulating material that solidifies after flowing, which not only insulates and fixes the conductor wire, but also conducts the heat energy emitted by the conductor wire to the inner and outer cooling water channel structures through heat conduction, achieving the purpose of heat dissipation. The water-cooled stator structure also includes an inner and outer communication water channel structure and a water-tight structure that connects between the inner and outer cooling water channel structures and the cooling water pipe, preventing the cooling water from leaking out.

[0022] The above description will be described in detail in the following embodiments, and the technical solutions of the present application will be further explained. BRIEF DESCRIPTION OF DRAWINGS

[0023] In order to make the above and other objects, features, advantages and embodiments of the present application more apparent, the following description of the accompanying drawings is as follows:

[0024] Figure 1 To show the perspective view of the water-cooled stator structure of the axial flux motor of an embodiment of the present application;

[0025] Figure 2 To show Figure 1 the cross-sectional view along the 2-2 section line;

[0026] Figure 3 To show Figure 1 the perspective view of the water-cooled stator structure of the axial flux motor of an embodiment of the present application after removing part of the outer ring water channel wall;

[0027] Figure 4 To show Figure 1 the perspective view of the water-cooled stator structure of the axial flux motor of an embodiment of the present application after removing the outer cooling water channel structure;

[0028] Figure 5 To show Figure 1 the perspective view of the water-cooled stator structure of the axial flux motor of an embodiment of the present application after removing the outer cooling water channel structure and the conductor wire;

[0029] Figure 6 To show Figure 5 the perspective view of the water-cooled stator structure of the axial flux motor of an embodiment of the present application after removing the outer upper circular ring of the outer communication water channel structure;

[0030] Figure 7 To show Figure 5 the perspective view of the water-cooled stator structure of the axial flux motor of an embodiment of the present application after removing the stator body; To show

[0031] Figure 8 To show Figure 7 A three-dimensional view of the water-cooled stator structure after removing the outer upper ring of the external connecting water channel structure;

[0032] Figure 9 To show Figure 7 A 3D view of the water-cooled stator structure after removing the external connecting water channel structure; and

[0033] Figure 10 To show Figure 8 A 3D view of the water-cooled stator structure after removing the inner upper ring of the internal connecting water channel structure.

[0034] The attached figures are labeled as follows:

[0035] 100: Water-cooled stator structure

[0036] 110:Stator body

[0037] 110a: Slot

[0038] 120: Conductor wire

[0039] 120°: Outer diameter protrusion

[0040] 120i: Inner diameter protrusion

[0041] 140: External cooling water channel structure

[0042] 140a: Outer ring waterway wall

[0043] 140b: Outer ring waterway wall

[0044] 140c: External cooling water passage

[0045] 142a, 142b, 142c: O-rings

[0046] 143a, 143b: Through holes

[0047] 144: Thermosetting Insulation Materials

[0048] 160: Internal cooling water channel structure

[0049] 160a: Inner ring waterway wall

[0050] 160b: Inner ring waterway wall

[0051] 160c: Internal cooling water passage

[0052] 161: Concave-convex features

[0053] 162a: O-ring

[0054] 162b: O-ring

[0055] 170: External connecting waterway structure

[0056] 170a: Outer upper ring

[0057] 170b: Outer lower ring

[0058] 171a: External connecting waterway

[0059] 171b: External connecting waterway

[0060] 172a: External connecting water hole

[0061] 172b: External connecting water hole

[0062] 180: Cooling water pipe

[0063] 180a, 180b: Ends

[0064] 182: External watertight structure

[0065] 184: Internal watertight structure

[0066] 190: Internal interconnected waterway structure

[0067] 190a: Inner upper ring

[0068] 190b: Inner lower ring

[0069] 191: Conical protrusion

[0070] AD: Axial

[0071] RD: Radial Detailed Implementation

[0072] To make the description of this invention more detailed and complete, reference can be made to the accompanying drawings and the various embodiments described below, in which the same numbers represent the same or similar elements. Furthermore, well-known elements and steps are not described in the embodiments to avoid unnecessarily limiting the invention. In the embodiments and claims, unless specifically defined herein, "a" and "the" may refer to one or more.

[0073] Please refer to Figure 1 , Figure 2 and Figure 3The water-cooled stator structure 100 includes a stator body 110, an inner cooling water channel structure 160, and an outer cooling water channel structure 140. The hollow annular stator body 110 has multiple slots 110a extending radially RD. Multiple conductor wires 120 pass through the corresponding slots 110a radially RD to form a distributed winding structure and windings, and have multiple inner diameter protrusions 120i and multiple outer diameter protrusions 120o. The multiple inner diameter protrusions 120i are located in an internal space of the stator body 110, and the multiple outer diameter protrusions 120o are exposed outside the outer diameter sidewall of the stator body 110. The axial flux motor includes a stator body 110 and a rotor body (not shown), and the stator body 110 and the rotor body at least partially overlap in the axial direction AD.

[0074] In some embodiments of the present invention, the internal cooling channel structure 160 is located within the internal space of the stator body 110, and a plurality of inner diameter protrusions 120i are located between the stator body 110 and the internal cooling channel structure 160. The internal cooling channel structure 160 includes two inner ring channel walls (160a, 160b) fitted together to form an internal cooling channel 160c between them, that is, the internal cooling channel 160c is formed between the two inner ring channel walls (160a, 160b). The internal cooling channel structure 160 also includes watertight structures such as O-rings (162a, 162b) clamped between the two inner ring channel walls (160a, 160b) to prevent water leakage. The O-rings (162a, 162b) contain an elastic polymer material or a colloidal material.

[0075] In some embodiments of the invention, an external cooling channel structure 140 surrounds the outer diameter sidewall of the stator body 110, wherein a plurality of outer diameter protrusions 120o are located between the stator body 110 and the external cooling channel structure 140. The external cooling channel structure 140 includes two outer ring channel walls (140a, 140b) fitted together to form an external cooling channel 140c between them, i.e., the external cooling channel 140c is formed between the two outer ring channel walls (140a, 140b). The external cooling channel structure 140 also includes watertight structures such as O-rings (142a, 142b, 142c) clamped between the two outer ring channel walls (140a, 140b) to prevent leakage. The O-rings (142a, 142b, 142c) comprise an elastic polymer or colloidal material.

[0076] In some embodiments of the present invention, a flow-before-curing thermosetting insulating material 144 can be filled between the stator body 110 and the outer cooling channel structure 140 and located between a plurality of outer diameter protrusions 120o, thereby fixing the stator body 110, the outer cooling channel structure 140 and the plurality of outer diameter protrusions 120o together and facilitating heat dissipation of the plurality of outer diameter protrusions 120o. The flow-before-curing thermosetting insulating material 144 can also be filled between the stator body 110 and the inner cooling channel structure 160 and located between a plurality of inner diameter protrusions 120i, thereby fixing the stator body 110, the inner cooling channel structure 160 and the plurality of inner diameter protrusions 120i together and facilitating heat dissipation of the plurality of inner diameter protrusions 120i. The flow-before-curing thermosetting insulating material 144 can also be filled between a plurality of conductor wires 120 and the stator body 110 to insulate and fix the plurality of conductor wires 120 and aid in heat conduction.

[0077] In some embodiments of the present invention, the stator body 110 may be composed of multiple silicon steel sheets stacked along the radial direction RD or along the axial direction AD, or may be composed of soft magnetic composite (SMC).

[0078] Please refer to Figure 4 , Figure 5 and Figure 6 An external connecting water channel structure 170 is located between the stator body 110 and the external cooling water channel structure 140, and is used to connect the cooling water pipe 180 and the external cooling water channel structure 140. The external connecting water channel structure 170 has external connecting water holes (172a, 172b) to connect to corresponding through holes (143a, 143b) and external cooling water channels 140c of the external cooling water channel structure 140, respectively. The external connecting water channel structure 170 includes an upper outer ring 170a and a lower outer ring 170b, which are fitted together to form a plurality of external connecting water channels (171a, 171b) arranged radially along the circumferential direction and extending radially RD. Each external connecting water channel (171a or 171b) is connected to a corresponding cooling water pipe 180. The external waterway structure 170 also has an external watertight structure 182 that contacts one end of a plurality of cooling water pipes 180 along the radial direction RD.

[0079] In some embodiments of the present invention, each external communication channel (171a or 171b) corresponds to a slot 110a of the stator body 110 in the radial direction RD. In some embodiments of the present invention, every two adjacent external communication channels 171a are connected to an external communication water hole 172a, and every two adjacent external communication channels 171b are connected to an external communication water hole 172b.

[0080] Please refer to the following at the same time Figure 7 and Figure 8In some embodiments of the present invention, multiple cooling water pipes 180 are made of a waterproof, non-magnetic material, effectively preventing internal cooling water from seeping out or directly contacting the soft magnetic material of the stator body 110. The cooling water pipes 180 pass radially through the stator body 110 and are located between the inner cooling water channel structure 160 and the outer cooling water channel structure 140. In some embodiments of the present invention, the outer watertight structure 182 is a ring structure located between the stator body 110 and the outer connecting water channel structure 170, for example, an O-ring. The outer watertight structure 182 comprises an elastic polymer or colloidal material. In some embodiments of the present invention, the outer watertight structure 182 allows multiple ends 180a of all cooling water pipes 180 to pass through, and the polymer or colloidal material of the outer watertight structure 182 can tightly adhere to the periphery of the multiple ends 180a of the cooling water pipes 180 to eliminate the possibility of leakage. In some embodiments of the present invention, the inner watertight structure 184 is a ring structure and is located between the stator body 110 and the inner connecting water channel structure 190, for example, an O-ring, which will be described in detail below.

[0081] Please refer to Figure 9 and Figure 10 In some embodiments of the present invention, the internally connected water channel structure 190 includes an inner upper ring 190a and an inner lower ring 190b, which are fitted together to form a plurality of internally connected water channels (192a, 192b) arranged radially along the circumferential direction and extending radially RD, respectively connecting to other ends 180b of a plurality of cooling water pipes 180 along the radial RD. An internal watertight structure 184 allows all the other ends 180b of the cooling water pipes 180 to pass through, and the polymer or colloidal material of the internal watertight structure 184 can tightly adhere to the periphery of the other ends 180b of the cooling water pipes 180 to prevent leakage. The internal cooling channel structure 160 includes two inner ring channel walls (160a, 160b) fitted together to form an internal cooling channel 160c between them, i.e., the internal cooling channel 160c is formed between the two inner ring channel walls (160a, 160b). The inner ring channel wall 160a closer to the stator body 110 has multiple protrusions and depressions 161, increasing the contact area with the stator body 110, the thermosetting insulating material 144 filling the multiple inner diameter protrusions 120i, and the inner ring channel wall 160a, thereby improving heat exchange efficiency. In some embodiments of the invention, the inner upper ring 190a of the internally connected channel structure 190 includes multiple conical protrusions 191 arranged in a ring along the circumferential direction, with the conical tips extending upward along the axial direction AD. Each conical protrusion 191 is located between every two adjacent inner diameter protrusions 120i (see also...). Figure 1 and Figure 2This improves the heat exchange efficiency between the conical protrusion 191 and the plurality of inner diameter protrusions 120i. Each inner connecting water channel (192a or 192b) connects to the corresponding cooling water pipe 180 and the inner cooling water channel 160c. Similarly, a plurality of conical protrusions 191 can be formed in the inner lower ring 190b, arranged in a ring along the circumferential direction, with the conical tips extending downward along the axial direction AD and extending into the space between every two adjacent inner diameter protrusions 120i.

[0082] The water-cooled stator structure of the axial flux motor of this invention uses a non-magnetic material that prevents water penetration as the cooling water pipes to connect the internal and external cooling water channels of the stator body, allowing cooling water to directly enter the stator interior, which has a high heat density, for heat exchange. The cooling water pipes pass through the soft magnetic material of the stator, effectively preventing internal cooling water from seeping out or directly contacting the soft magnetic material. A thermosetting insulating material that first flows and then cures is used to fill the space between the internal and external cooling water channel structures and the conductor wires (inner or outer diameter protrusions). Besides insulating and fixing the conductor wires, the thermosetting insulating material also conducts heat generated by the conductor wires to the internal and external cooling water channel structures, achieving heat dissipation. The water-cooled stator structure also includes an internal and external connecting water channel structure and a watertight structure connecting the internal and external cooling water channel structures and the cooling water pipes to prevent cooling water leakage.

[0083] Although the present invention has been disclosed above with reference to embodiments, it is not intended to limit the present invention. Those skilled in the art can make various modifications and refinements without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention shall be determined by the appended claims.

Claims

1. A water-cooled stator structure for an axial flux motor, comprising: A hollow annular stator body with multiple slots; Multiple conductor wires pass through multiple slots in a radial direction to form a distributed winding structure, and have multiple inner diameter protrusions and multiple outer diameter protrusions. The multiple inner diameter protrusions are located in an internal space of the stator body, and the multiple outer diameter protrusions are exposed outside an outer diameter sidewall of the stator body. Multiple cooling water pipes, made of waterproof, non-magnetic material, pass through the stator body radially and are located between the internal space and the outer diameter sidewall; An internally connected waterway structure is connected to a plurality of said cooling water pipes and has an internal watertight structure in contact with one end of each of said plurality of said cooling water pipes; An externally connected waterway structure, connected to a plurality of said cooling water pipes, and having an external watertight structure contacting the other end of each of said cooling water pipes; and A thermosetting insulating material is filled between the plurality of inner diameter protrusions, the plurality of outer diameter protrusions, the inner connecting waterway structure, and the outer connecting waterway structure.

2. The water-cooled stator structure of the axial flux motor as described in claim 1, wherein the stator body is a soft magnetic material body, and the plurality of cooling water pipes are arranged radially and pass through the stator body.

3. The water-cooled stator structure of the axial flux motor as described in claim 1, wherein the inner connecting water channel structure includes an inner upper ring and an inner lower ring fitted together to form a plurality of radially arranged inner connecting water channels, which respectively connect to the ends of the plurality of cooling water pipes.

4. The water-cooled stator structure of the axial flux motor as described in claim 3, wherein the inner watertight structure is located between the stator body and the inner connecting water channel structure.

5. The water-cooled stator structure of the axial flux motor as claimed in claim 1, wherein the external connecting water channel structure includes an outer upper ring and an outer lower ring fitted together to form a plurality of radially arranged external connecting water channels, which respectively connect to the other end of the plurality of cooling water pipes.

6. The water-cooled stator structure of the axial flux motor as described in claim 5, wherein the external watertight structure is located between the stator body and the external connecting water channel structure.

7. The water-cooled stator structure of the axial flux motor as claimed in claim 1, wherein the inner watertight structure or the outer watertight structure comprises an elastic polymer material or a colloidal material.

8. The water-cooled stator structure of the axial flux motor as described in claim 1, wherein the internally connected water channel structure comprises a plurality of conical protrusions arranged along a circumferential direction.

9. The water-cooled stator structure of the axial flux motor as claimed in claim 8, wherein each of the conical protrusions is located between every two adjacent of the plurality of inner diameter protrusions.

10. The water-cooled stator structure of the axial flux motor as described in claim 1, further comprising: An internal cooling water channel structure is located within the internal space of the stator body, wherein a plurality of said inner diameter protrusions are located between the stator body and the internal cooling water channel structure; and An external cooling water channel structure surrounds the outer diameter sidewall of the stator body, wherein a plurality of said outer diameter protrusions are located between the stator body and the external cooling water channel structure.

11. The water-cooled stator structure of the axial flux motor as claimed in claim 10, wherein the thermosetting insulating material is further filled between the stator body, the external cooling water channel structure and the plurality of outer diameter protrusions.

12. The water-cooled stator structure of the axial flux motor as claimed in claim 10, wherein the thermosetting insulating material is further filled between the stator body, the internal cooling water channel structure and the plurality of inner diameter protrusions.

13. The water-cooled stator structure of the axial flux motor as described in claim 10, wherein the inner cooling channel structure comprises two inner ring water channel walls that fit together to form an inner cooling channel between the two inner ring water channel walls.

14. The water-cooled stator structure of the axial flux motor as claimed in claim 13, wherein the inner ring water channel wall near the stator body has a plurality of concave and convex features, and the thermosetting insulating material is filled between the stator body, the plurality of inner diameter protrusions, the inner ring water channel wall and the plurality of concave and convex features.

15. The water-cooled stator structure of the axial flux motor as described in claim 10, wherein the outer cooling channel structure comprises two outer ring water channel walls that fit together to form an outer cooling channel between the two outer ring water channel walls.

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