electric machine

Abstract

An electric machine includes a machine housing and a stator including a stator core defining a stator core interior and a plurality of windings disposed in the stator core interior. The plurality of windings has a first end winding and a second end winding. The electric machine further includes an inner core surrounding the plurality of windings within the stator core interior. The inner core includes a first upper portion, a second upper portion, a first lower portion, and a second lower portion. The electric machine includes a first insert portion surrounding a first plurality of windings. The first insert portion is engaged with the inner core to define a first cooling channel for encasing the first end winding. The electric machine also includes a second insert portion surrounding a second plurality of windings. The second insert portion is engaged with the inner core to define a second cooling channel for encasing the second end winding.

Description

[0001] Cross-reference to related applications This application claims priority and all benefits to U.S. Provisional Patent Application No. 63 / 729,599, filed December 9, 2024, which is hereby expressly incorporated herein by reference in its entirety. Technical Field

[0002] This subject matter relates to the field of electric motors, and particularly to electric motors used in drive module assemblies. Background Technology

[0003] Traditional drive module components include an electric motor configured to transmit rotational torque to the wheels of a vehicle. To facilitate the transmission of rotational torque to the wheels of the vehicle, traditional drive module components include gears and differentials to ultimately transmit rotational torque from the electric motor to the wheels of the vehicle, allowing the vehicle to be maneuvered.

[0004] As hybrid and battery electric vehicles (NEVs) become more prevalent, the need for efficient and reliable drive module assemblies has become increasingly important. One of the main challenges in designing drive module assemblies for NEVs is achieving high efficiency while maintaining a compact size and low weight. NEVs typically have limited available space for drive module assemblies, and any added weight can reduce the vehicle's range and performance.

[0005] In recent years, advancements in electric motor technology and power electronics have led to the development of more compact and efficient drive module assemblies. Furthermore, these advancements have increased the power output and rotational speed of various electric motors, resulting in increased heat generation. Therefore, adequately cooling electric motors remains a challenge. Consequently, there is still a need for motors with improved cooling capabilities, while simultaneously achieving improved efficiency and enhanced performance, addressing the shortcomings described above. Summary of the Invention

[0006] An electric motor includes a housing defining an interior. The motor includes a stator disposed within the housing and extending along a stator axis. The stator includes a stator core defining an interior stator body and a plurality of windings disposed within the stator core. The plurality of windings have a first end winding extending along the stator axis in a first direction to an outer side of the interior stator core and a second end winding extending along the stator axis in a second direction opposite to the first direction to an outer side of the interior stator core. The motor further includes an inner core surrounding the plurality of windings within the stator core. The inner core includes: a first upper portion facing the first direction; a second upper portion spaced from the first upper portion along the stator axis and facing the second direction; a first lower portion disposed between the first upper portion and the stator axis and facing the first direction; and a second lower portion disposed between the second upper portion and the stator axis and facing the second direction. The motor includes a first insertion portion surrounding the first plurality of windings. The first insert engages with the inner core to define a first cooling channel for encapsulating a first end winding. The motor also includes a second insert that surrounds a second plurality of windings. The second insert engages with the inner core to define a second cooling channel for encapsulating a second end winding. Attached Figure Description

[0007] Other advantages of the invention will be readily recognized, as they become better understood when taken in conjunction with the following detailed description and the accompanying drawings.

[0008] Figure 1 This is a perspective view of the motor.

[0009] Figure 2 This is a perspective view of the stator and inner core of the motor.

[0010] Figure 3 It is a cross-sectional view of the inner core and the stator including multiple windings.

[0011] Figure 4 This is a cross-sectional view of an electric motor, wherein the inner core includes: a first upper portion facing a first direction; a second upper portion spaced apart from the first upper portion along a stator axis and facing a second direction; a first lower portion disposed between the first upper portion and the stator axis and facing the first direction; and a second lower portion disposed between the second upper portion and the stator axis and facing the second direction. The motor further includes: a first insertion portion surrounding a first end winding, wherein the first insertion portion engages with the inner core to define a first cooling channel for encapsulating the first end winding; and a second insertion portion surrounding a second end winding, wherein the second insertion portion engages with the inner core to define a second cooling channel for encapsulating the second end winding.

[0012] Figure 5It is a side cross-sectional view of the motor, wherein the motor includes a first supply path and a first supply inlet.

[0013] Figure 6 It is a side cross-sectional view of the motor, wherein the motor includes a first outlet path and a first outlet.

[0014] Figure 7 It is a cross-sectional view of the drive module assembly, including the motor and gear set.

[0015] Figure 8 This is an enlarged cross-sectional view of the first insertion portion engaging with the inner core to define a first cooling channel for encapsulating the first end winding.

[0016] Figure 9 It is an enlarged perspective cross-sectional view of the first insertion portion engaging with the inner core to define a first cooling channel for encapsulating the first end winding.

[0017] Figure 10 It is an enlarged perspective cross-sectional view of a first insert portion surrounding a first end winding, wherein the first insert portion engages with an inner core to define a first cooling channel for encapsulating the first end winding.

[0018] Figure 11 This is an enlarged cross-sectional view of another embodiment where the first insertion portion engages with the inner core to define a first cooling channel for encapsulating the first end winding.

[0019] Figure 12 This is an enlarged cross-sectional view of another embodiment where the second insertion portion engages with the inner core to define a second cooling channel for encapsulating the second end winding. Detailed Implementation

[0020] Referring to the accompanying drawings, where similar reference numerals indicate similar parts in several views, motor 20 is generally located in... Figure 1 As shown in [the image / document]. Figure 7 As shown, the motor 20 can be used in the drive module assembly 22, which includes the motor 20 and a gear set 24 rotatably coupled to the output 26 of the motor 20. The motor 20 is configured to transmit rotational torque to the wheels of the vehicle via the gear set 24. The vehicle may include an internal combustion engine and is therefore a hybrid vehicle. The vehicle may also be a battery electric vehicle without an internal combustion engine. It will be appreciated that the vehicle may include one or more drive module assemblies 22, such as two drive module assemblies.

[0021] refer to Figure 1 and Figure 4 The motor 20 includes a machine housing 27 defining an interior 28 of the machine housing. The motor 20 also includes a stator 30 disposed within the machine housing 28 and extending along a stator axis SA. Figures 1 to 4 As shown, the stator 30 includes a stator core 32 defining a stator core interior 34 and a plurality of windings 36 disposed within the stator core interior 34. The stator core 32 may be a plurality of stator laminates. The plurality of windings 36 have a first end winding 38 extending along the stator axis SA in a first direction FD to the outside of the stator core interior 34 and a second end winding 40 extending along the stator axis SA in a second direction SD opposite to the first direction FD to the outside of the stator core interior 34.

[0022] Special Reference Figure 1 and Figure 4 The motor 20 also includes a rotor 42 disposed within the stator core 34 and extending along the rotor axis RA. The rotor 42 defines the rotor interior 44 disposed around the rotor axis RA. (As in...) Figure 7 As shown, motor 20 may include a differential 46 disposed within rotor 44 and rotatably coupled to rotor 42. Motor 20 may include a first input shaft 48 rotatably coupled to differential 46 and a second input shaft 50 rotatably coupled to differential 46.

[0023] Refer again Figures 1 to 4 The motor 20 includes an inner core 52 that surrounds a plurality of windings within a stator core interior 34. The inner core 52 may be further defined as an overmolded core. When present, the overmolded core includes an overmolded material. The overmolded material may include high-temperature plastics, thermosetting materials, polyphenylene sulfide (PPS), thermoplastic materials, heat-transferring materials, etc., and may be formed by an injection molding process. The inner core 52 may encapsulate each of the plurality of windings 36 along the stator axis SA. The inner core 52 may engage with each of the plurality of windings 36. Typically, the inner core 52 and the stator core 32 are separate components (i.e., two or more pieces). Typically, the inner core 52 and the stator core 32 comprise different materials. For example, as mentioned above, the stator core 32 may be a plurality of laminates comprising electrical steel, and the inner core 52 may be an overmolded material.

[0024] The inner core 52 includes: a first upper portion 86 facing a first direction FD; a second upper portion 88 spaced apart from the first upper portion 86 along the stator axis SA and facing a second direction SD; a first lower portion 90 disposed between the first upper portion 86 and the stator axis SA and facing the first direction FD; and a second lower portion 92 disposed between the second upper portion 88 and the stator axis SA and facing the second direction SD. The first upper portion 86, the second upper portion 88, the first lower portion 90, and the second lower portion 92 may be referred to as a sealing extrusion section. The first upper portion 86, the second upper portion 88, the first lower portion 90, and the second lower portion 92 may be integral with each other.

[0025] The inner core 52 may include a main body portion 93 disposed within the stator core 32. A first upper portion 86 and a first lower portion 90 extend from the main body portion 93 in a first direction FD, and a second upper portion 88 and a second lower portion 92 extend from the main body portion 93 in a second direction. Typically, the main body portion 93, the first upper portion 86, the first lower portion 90, the second upper portion 88, and the second lower portion 92 are integrally formed (i.e., one piece).

[0026] The motor 20 includes a first insertion portion 94 that surrounds a first end winding 38. The first insertion portion 94 engages with an inner core 52 to define a first cooling channel 54 for encapsulating the first end winding 38. The motor 20 also includes a second insertion portion 96 that surrounds a second end winding 40. The second insertion portion 96 engages with the inner core 52 to define a second cooling channel 56 for encapsulating the second end winding. The inner core 52 may include a body portion 93 disposed within a stator core 32. A first upper portion 86 and a first lower portion 90 extend from the body portion 93 in a first direction FD, and a second upper portion 88 and a second lower portion 92 extend from the body portion 93 in a second direction.

[0027] Engaging the first insertion portion 94 with the inner core 52 to define a first cooling channel 54 for encapsulating the first end winding 38 and enclosing the second end winding 40 with the second insertion portion 96 to define a second cooling channel 56 for encapsulating the second end winding 40 allows for several advantages. First, engaging the first insertion portion 94 with the inner core 52 to define the first cooling channel 54 for encapsulating the first end winding 38 and encapsulating the second end winding 40 with the second insertion portion 96 to define the second cooling channel 56 for encapsulating the second end winding 40 allows for a complete seal between the first cooling channel 54 and the second cooling channel 56, such that fluid entry into and exit from the first cooling channel 54 and the second cooling channel 56 are associated only with their respective inlets and outlets.

[0028] Second, engaging the first insertion portion 94 with the inner core 52 to define a first cooling channel 54 for encapsulating the first end winding 38 and engaging the second insertion portion 96 with the inner core 52 to define a second cooling channel 56 for encapsulating the second end winding 40 allows for ease of manufacture and design flexibility, as the first insertion portion 94 and the second insertion portion 96 can be designed based on each specific application.

[0029] Third, the first insertion portion 94 engaging with the inner core 52 to define a first cooling channel 54 for encapsulating the first end winding 38, and the second insertion portion 96 surrounding the second end winding 40 and engaging with the inner core 52 to define a second cooling channel 56 for encapsulating the second end winding 40, allows for better cooling of the stator 32 because the components defining the first cooling channel 54 and the second cooling channel 56 do not merely engage with the stator core 32, which allows for better heat dissipation. In one embodiment, the first insertion portion 94 engages directly with the first upper portion 86 and the first lower portion 90, and the second insertion portion 96 engages directly with the second upper portion 88 and the second lower portion 92. In yet another embodiment, the first insertion portion 94 engages only directly with the first upper portion 86 and the first lower portion 90 to form a seal, and the second insertion portion 96 engages only directly with the second upper portion 88 and the second lower portion 92 to form a seal. In other words, the first insertion portion 94 does not engage with the stator core 32, and the second insertion portion 96 does not engage with the stator core 32, which allows for better heat dissipation. Furthermore, engaging the first insertion portion 94 with the first upper portion 86 and the first lower portion 90, and engaging the second insertion portion 96 with the second upper portion 88 and the second lower portion 92, allows the formation of the first cooling channel 54 and the second cooling channel 56 without the use of fasteners, which are typically engaged with various components of the motor and the stator core to form the first and second cooling channels. However, the engagement of various fasteners with the stator core can negatively affect the throughput of the stator core, and such fasteners often overheat and require further cooling. For this purpose, engaging the first insertion portion 94 with the first upper portion 86 and the first lower portion 90, and engaging the second insertion portion 96 with the second upper portion 88 and the second lower portion 92, eliminates the need for the use of any fasteners, as the first cooling channel 54 and the second cooling channel 56 can be formed without the use of fasteners.

[0030] Furthermore, engaging the first insertion portion 94 with the first upper portion 86 and the first lower portion 90, and engaging the second insertion portion 96 with the second upper portion 88 and the second lower portion 92, allows for blind assembly of the motor 20, particularly when the first cooling channel 54 and the second cooling channel 56 are formed during the assembly of the motor 20. Moreover, engaging the first insertion portion 94 with the first upper portion 86 and the first lower portion 90, and engaging the second insertion portion 96 with the second upper portion 88 and the second lower portion 92, eliminates the need to use magnetic materials (such as steel) for assembling the motor 20, and particularly for securing the enclosure to define the first and second cooling channels. Using magnetic steel for fasteners, and particularly for fasteners to the stator core itself, can negatively alter the magnetic flux and cause the steel magnetic fasteners to overheat. Furthermore, engaging the first insertion portion 94 with the first upper portion 86 and the first lower portion 90, and engaging the second insertion portion 96 with the second upper portion 88 and the second lower portion 92, allows the first insertion portion 94, the second insertion portion 96, and the inner core 52 to have substantially similar or identical coefficients of thermal expansion.

[0031] refer to Figures 8 to 10 The first upper portion 86 may include a first upper surface 98, and the first lower portion 90 includes a first lower surface 100. The first insertion portion 94 may have a first upper arm 102 extending toward and engaging the first upper surface 98 to define a first cooling channel 54, and the first insertion portion 94 may have a first lower arm 104 extending toward and engaging the first lower surface 100 to further define the first cooling channel 54. In one embodiment, the first upper arm 102 engages directly with the first upper surface 98, and the first lower arm 104 engages directly with the first lower surface 100. The first insertion portion 94 may have a U-shaped configuration.

[0032] As in Figures 8 to 10 As shown, the first upper surface 98 can be oriented perpendicularly to the stator axis SA, such that the first upper surface 98 faces a first direction, and the first lower surface 100 can be oriented parallel to the stator axis SA, such that the first lower surface 100 faces the stator axis. Orienting the first lower surface 100 parallel to the stator axis SA allows for easier mounting of the rotor 42.

[0033] Continue to refer to Figures 8 to 10The motor 20 may include a first upper gasket 106 disposed between a first upper surface 98 and a first upper arm 102, wherein the first upper gasket 106 is axially compressed between the first upper surface 98 and the first upper arm 102 about the stator axis SA. The motor 20 may also include a first lower gasket 108 disposed between a first lower surface 100 and a first lower arm 104, wherein the first lower gasket 108 is radially compressed between the first lower surface 100 and the first lower arm 104 about the stator axis SA.

[0034] refer to Figure 11 and Figure 12 The first upper surface 98 may be oriented parallel to the stator axis SA, such that the first upper surface 98 faces the stator axis SA, and the first lower surface 100 may be oriented parallel to the stator axis SA, such that the first lower surface 100 faces the stator axis SA. In such an embodiment, a first upper gasket 106 may be disposed between the first upper surface 98 and the first upper arm 102, wherein the first upper gasket 106 is radially compressed between the first upper surface 98 and the first upper arm 102 about the stator axis SA, and a first lower gasket 108 may be disposed between the first lower surface 100 and the first lower arm 104, wherein the first lower gasket 108 is radially compressed between the first lower surface 100 and the first lower arm 104 about the stator axis SA.

[0035] The inner core 52 may include a first lower protrusion 110 that extends away from the stator core interior 34 in a first direction FD, wherein the first lower protrusion 110 includes a first lower surface 100.

[0036] The machine housing 27 may define a first insertion cavity 112, which is configured and formed to receive the first insertion portion 94. The first insertion portion 94 and the machine housing 27 may engage with each other, and in one embodiment, the first insertion portion 94 and the machine housing 27 may engage directly with each other.

[0037] It will be recognized that, similar to, in Figures 8 to 10In the embodiment shown regarding the first cooling channel 54 side of the motor 20, the second upper portion 88 may include a second upper surface 114, and the second lower portion 92 may similarly include a second lower surface 116. Although not explicitly shown in the figures, the second insertion portion 96 may have a second upper arm 118 extending toward and engaging the second upper surface 114 to define the second cooling channel 56, and the second insertion portion 96 may have a second lower arm 120 extending toward and engaging the second lower surface 116 to further define the second cooling channel 56. In one embodiment, the second upper arm 118 engages directly with the second upper surface 114, and the second lower arm 120 engages directly with the second lower surface 116. The second insertion portion 96 may have a U-shaped configuration.

[0038] The second upper surface 114 may be oriented perpendicularly to the stator axis SA, such that the second upper surface 114 faces the first direction FD, and the second lower surface 116 may be oriented parallel to the stator axis SA, such that the second lower surface 116 faces the stator axis SA. Orienting the second lower surface 116 parallel to the stator axis SA allows for easier installation of the rotor 42.

[0039] The motor 20 may include a second upper gasket 122 disposed between a second upper surface 114 and a second upper arm 118, wherein the second upper gasket 122 is axially compressed between the second upper surface 114 and the second upper arm 118 about the stator axis SA. The motor 20 may also include a second lower gasket 124 disposed between a second lower surface 116 and a second lower arm 120, wherein the second lower gasket 124 is radially compressed between the second lower surface 116 and the second lower arm 120 about the stator axis SA.

[0040] refer to Figure 11 and Figure 12 In the embodiment shown, the second upper surface 114 may be oriented parallel to the stator axis SA, such that the first upper surface 114 faces the stator axis SA, and the second lower surface 116 may be oriented parallel to the stator axis SA, such that the second lower surface 116 faces the stator axis SA. In such an embodiment, a second upper gasket 122 may be disposed between the second upper surface 114 and the second upper arm 118, wherein the second upper gasket 122 is radially compressed between the second upper surface 114 and the second upper arm 118 about the stator axis SA, and a second lower gasket 124 may be disposed between the second lower surface 116 and the second lower arm 120, wherein the second lower gasket 124 is radially compressed between the second lower surface 116 and the second lower arm 120 about the stator axis SA.

[0041] The inner core 52 may include a second lower protrusion 126 that extends away from the stator core interior 34 in a second direction SD, wherein the second lower protrusion 126 includes a second lower surface 116.

[0042] The machine housing 27 may define a second insertion cavity 128, which is configured to receive the second insertion portion 94. The first insertion portion 94 and the machine housing 27 may engage with each other, and in one embodiment, the first insertion portion 94 and the machine housing 27 may engage directly with each other.

[0043] refer to Figures 1 to 4 The inner core 52 may be in direct contact with the plurality of windings 36 within the stator core interior 34, such that the stator 30 has no fluid path connecting the first cooling channel 54 and the second cooling channel 56. Alternatively or additionally, the inner core 52 and the plurality of windings 36 may define a barrier surface 76 perpendicular to the stator axis SA, wherein the barrier surface 76 is continuous within the stator core interior 34, such that the stator 30 has no fluid path connecting the first cooling channel 54 and the second cooling channel 56. The stator 30 may be without insulating paper between the plurality of windings, particularly in embodiments described above in which the inner core 52 is in direct contact with the plurality of windings 36 within the stator core interior 34, and / or when the inner core 52 and the plurality of windings 36 define a continuous barrier surface 76 within the stator core interior 34, such that the stator 30 has no fluid path connecting the first cooling channel 54 and the second cooling channel 56.

[0044] The motor 20 may include: a first supply path 58 configured to guide fluid to a first cooling channel 54 through a first supply inlet 62; and a second supply path 60 configured to guide fluid to a second cooling channel 56 through a second supply inlet 64. Typically, an inner core 52 is disposed between the first supply inlet 62 and the second supply inlet 64, such that the inner core 52 separates the fluid in the first supply path 58 and the second supply path 60. The motor 20 may further include: a first outlet path 66 configured to guide fluid from the first cooling channel 54 to a storage unit 70 through a first outlet 68; and a second outlet path 72 configured to guide fluid from the second cooling channel 56 to the storage unit 70 through a second outlet 74.

[0045] In one embodiment, the first cooling channel 54 and the second cooling channel 56 are fluidly separated from each other. In other words, fluid from the first cooling channel 54 cannot enter the second cooling channel 56, and fluid from the second cooling channel 56 cannot enter the first cooling channel 54. It will be appreciated that fluid from both the first cooling channel 54 and the second cooling channel 56 may enter a single storage unit, or fluid from the first cooling channel 54 may enter the first storage unit and fluid from the second cooling channel 56 may enter the second storage unit. In either embodiment, after the fluid leaves the storage unit, the fluid entering the first supply path 58 remains separated from the fluid entering the second supply path 60, and therefore, the first cooling channel 54 and the second cooling channel 56 are fluidly separated from each other.

[0046] As in Figure 5 and Figure 6 As best illustrated, a first supply path 58 may extend helically around the stator axis SA, and a second supply path 60 may extend helically around the stator axis SA. It will be appreciated that the first supply path 58 and the second supply path 60 may extend helically around the stator axis SA at zero pitch angles and any pitch angle greater than zero. The first supply path 58 may be fluid-separated from the second supply path 60, such that the first supply path 58 independently supplies fluid to the first cooling passage 54, and the second supply path 60 independently supplies fluid to the second cooling passage 56.

[0047] As in Figure 4 and Figure 7 As shown, the machine housing 27 may be further defined as a first machine housing 78 and a second machine housing 80 coupled to the first machine housing 78. The first machine housing 78 may be at least partially embedded within the second machine housing 80. (As shown in...) Figure 1As shown, the second housing 80 is removed to reveal the stator 30, inner core 52, and rotor 42. When present, the first housing 78 at least partially defines a first cooling channel 54 with the inner core 52, and the second housing 80 at least partially defines a second cooling channel 56 with the inner core 52. In one embodiment, a first supply path 58 is defined by the first housing 78, and a second supply path 60 is defined by the second housing 80. In such an embodiment, the first housing 78 may have a first inner housing surface 82 facing the stator axis SA, the second housing 80 may have a second inner housing surface 84 facing the stator axis SA, and the first supply path 58 may be defined by the first inner housing surface 82, and the second supply path 60 may be defined by the second inner housing surface 84. For example, the first supply path 58 may be entirely defined by the first housing 78, and the second supply path 60 may be entirely defined by the second housing 80. It is envisioned that the first supply path 58 and the second supply path 60 may be jointly defined between the first machine housing 78 and the second machine housing 80 and one or more components, as described below.

[0048] Example 1: An electric motor, comprising: The machine housing, which defines the interior of the machine housing; A stator disposed within the machine housing and extending along a stator axis, wherein the stator includes a stator core defining a stator core interior and a plurality of windings disposed within the stator core, and wherein the plurality of windings have a first end winding extending along the stator axis in a first direction to an outer side of the stator core interior and a second end winding extending along the stator axis in a second direction opposite to the first direction to an outer side of the stator core interior; An inner core that surrounds the plurality of windings within the stator core, the inner core comprising... The first upper portion faces the first direction. The second upper portion is spaced apart from the first upper portion along the stator axis and faces the second direction. The first lower portion, which is disposed between the first upper portion and the stator axis and faces the first direction, and The second lower portion is disposed between the second upper portion and the stator axis and faces the second direction; A first insertion portion surrounds the first end winding, wherein the first insertion portion engages with the inner core to define a first cooling channel for encapsulating the first end winding; and A second insertion portion surrounds the second end winding, wherein the second insertion portion engages with the inner core to define a second cooling channel for encapsulating the second end winding.

[0049] Example 2: The motor according to Example 1, wherein the first upper portion includes a first upper surface, wherein the first lower portion includes a first lower surface, wherein the first insertion portion has a first upper arm that extends toward the first upper surface and engages the first upper surface to define the first cooling channel, and wherein the first insertion portion has a first lower arm that extends toward the first lower surface and engages the first lower surface to further define the first cooling channel.

[0050] Example 3: The motor according to Example 2, wherein the first upper surface is oriented perpendicularly to the stator axis such that the first upper surface faces the first direction, and wherein the first lower surface is oriented parallel to the stator axis such that the first lower surface faces the stator axis.

[0051] Example 4: The motor according to Example 3 further includes a first upper gasket disposed between the first upper surface and the first upper arm, wherein the first upper gasket is axially compressed between the first upper surface and the first upper arm about the stator axis, and the motor further includes a first lower gasket disposed between the first lower surface and the first lower arm, wherein the first lower gasket is radially compressed between the first lower surface and the first lower arm about the stator axis.

[0052] Example 5: The motor according to any one of Examples 1 and 2, wherein the first upper surface is oriented parallel to the stator axis such that the first upper surface faces the stator axis, and wherein the first lower surface is oriented parallel to the stator axis such that the first lower surface faces the stator axis.

[0053] Example 6: The motor according to Example 5 further includes a first upper gasket disposed between the first upper surface and the first upper arm, wherein the first upper gasket is radially compressed between the first upper surface and the first upper arm about the stator axis, and the motor further includes a first lower gasket disposed between the first lower surface and the first lower arm, wherein the first lower gasket is radially compressed between the first lower surface and the first lower arm about the stator axis.

[0054] Example 7: The motor according to any one of Examples 2-6, wherein the inner core includes a first lower protrusion that extends away from the interior of the stator core in the first direction, and wherein the first lower protrusion includes a first lower surface.

[0055] Example 8: The motor according to any one of the foregoing embodiments, wherein the first insertion portion has a U-shaped structure.

[0056] Example 9: The motor according to any one of the foregoing embodiments, wherein the machine housing defines a first insertion cavity, the first insertion cavity being configured to receive the first insertion.

[0057] Example 10: The motor according to any one of the foregoing embodiments, wherein the first insertion part and the machine housing are engaged with each other.

[0058] Example 11: The motor according to any one of the foregoing embodiments further includes a first supply path, the first supply path being configured to guide fluid to the first cooling channel through a first supply outlet defined by the first insertion portion.

[0059] Example 12: The motor according to any one of the preceding embodiments, wherein the second upper portion includes a second upper surface, wherein the second lower portion includes a second lower surface, wherein the second insertion portion has a second upper arm that extends toward the second upper surface and engages the second upper surface to define the second cooling channel, and wherein the second insertion portion has a second lower arm that extends toward the second lower surface and engages the second lower surface to further define the second cooling channel.

[0060] Example 13: The motor according to Example 12, wherein the second upper surface is oriented perpendicularly to the stator axis such that the second upper surface faces the second direction, and wherein the second lower surface is oriented parallel to the stator axis such that the first lower surface faces the stator axis.

[0061] Example 14: The motor according to any one of Examples 12 and 13 further includes a second upper liner disposed between the second upper surface and the second upper arm, wherein the second upper liner is axially compressed between the second upper surface and the second upper arm about the stator axis, and the motor further includes a second lower liner disposed between the second lower surface and the second lower arm, wherein the second lower liner is radially compressed between the second lower surface and the second lower arm about the stator axis.

[0062] Example 15: The motor according to Example 12, wherein the second upper surface is oriented parallel to the stator axis such that the second upper surface faces the stator axis, and wherein the second lower surface is oriented parallel to the stator axis such that the second lower surface faces the stator axis.

[0063] Example 16: The motor according to Example 15 further includes a second upper liner disposed between the second upper surface and the second upper arm, wherein the second upper liner is radially compressed between the second upper surface and the second upper arm about the stator axis, and the motor further includes a second lower liner disposed between the second lower surface and the second lower arm, wherein the second lower liner is radially compressed between the second lower surface and the second lower arm about the stator axis.

[0064] Example 17: The motor according to any one of Examples 12-16, wherein the inner core includes a second lower protrusion that extends away from the interior of the stator core in the second direction, and wherein the second lower protrusion includes a second lower surface.

[0065] Example 18: The motor according to any one of the foregoing embodiments, wherein the first insertion portion has a U-shaped structure.

[0066] Example 19: The motor according to any one of the preceding embodiments, wherein the machine housing defines a second insertion cavity, the second insertion cavity being configured to receive the second insertion.

[0067] Example 20: The motor according to any one of the foregoing embodiments, wherein the second insertion part and the machine housing are engaged with each other.

[0068] Example 21: The motor according to any one of the foregoing embodiments, wherein the first upper portion, the second upper portion, the first lower portion and the second lower portion are integrally formed with each other.

[0069] Example 22: The motor according to any one of the foregoing embodiments, wherein the inner core further includes a main body portion, wherein the main body portion is disposed in the stator core, and the first upper portion and the first lower portion extend from the main body portion in the first direction, and the second upper portion and the second lower portion extend from the main body portion in the second direction.

[0070] Example 23: The motor according to any one of the preceding embodiments, wherein the first insertion portion is cylindrically arranged around the stator axis in a 360-degree configuration.

[0071] Example 24: The motor according to any one of the preceding embodiments, wherein the second insertion portion is cylindrically arranged around the stator axis in a 360-degree configuration.

[0072] Example 25: The motor according to any one of the foregoing embodiments, wherein the inner core is further defined as an overmolded core.

[0073] Example 26: The motor according to any one of the preceding embodiments, wherein the inner core is in direct contact with the plurality of windings inside the stator core, such that the stator has no fluid path that fluidly connects the first cooling channel and the second cooling channel.

[0074] Example 27: The motor according to any one of the foregoing embodiments, wherein the inner core and the stator core are separate components.

[0075] Example 28: The motor according to any one of the preceding embodiments, wherein the inner core and the plurality of windings define a barrier surface perpendicular to the stator axis, and wherein the barrier surface is continuous within the stator core such that the stator has no fluid path that fluidly connects the first cooling channel and the second cooling channel.

[0076] Example 29: The motor according to any one of the foregoing embodiments further includes a rotor disposed inside the stator housing and extending along the rotor axis.

[0077] Example 30: A drive module assembly includes a motor according to any one of the foregoing embodiments, and further includes a gear set rotatably coupled to the output of the motor, the gear set being configured to transmit rotational torque to the wheels of a vehicle.

Claims

1. An electric motor, comprising: The machine housing, which defines the interior of the machine housing; A stator disposed within the machine housing and extending along a stator axis, wherein the stator includes a stator core defining a stator core interior and a plurality of windings disposed within the stator core, and wherein the plurality of windings have a first end winding extending along the stator axis in a first direction to an outer side of the stator core interior and a second end winding extending along the stator axis in a second direction opposite to the first direction to an outer side of the stator core interior; An inner core that surrounds the plurality of windings within the stator core, the inner core comprising... The first upper portion faces the first direction. The second upper portion is spaced apart from the first upper portion along the stator axis and faces the second direction. The first lower portion, which is disposed between the first upper portion and the stator axis and faces the first direction, and The second lower portion is disposed between the second upper portion and the stator axis and faces the second direction; A first insertion portion surrounds the first end winding, wherein the first insertion portion engages with the inner core to define a first cooling channel for encapsulating the first end winding; and A second insertion portion surrounds the second end winding, wherein the second insertion portion engages with the inner core to define a second cooling channel for encapsulating the second end winding.

2. The motor according to claim 1, wherein, The first upper portion includes a first upper surface, wherein the first lower portion includes a first lower surface, wherein the first insertion portion has a first upper arm that extends toward and engages the first upper surface to define the first cooling channel, and wherein the first insertion portion has a first lower arm that extends toward and engages the first lower surface to further define the first cooling channel.

3. The motor according to claim 2, wherein, The first upper surface is oriented perpendicularly to the stator axis such that the first upper surface faces the first direction, and wherein the first lower surface is oriented parallel to the stator axis such that the first lower surface faces the stator axis.

4. The motor according to claim 3, further comprising a first upper gasket disposed between the first upper surface and the first upper arm, wherein, The first upper liner is axially compressed between the first upper surface and the first upper arm about the stator axis, and the motor further includes a first lower liner disposed between the first lower surface and the first lower arm, wherein the first lower liner is radially compressed between the first lower surface and the first lower arm about the stator axis.

5. The motor according to claim 2, wherein, The inner core includes a first lower protrusion that extends away from the interior of the stator core in the first direction, and wherein the first lower protrusion includes a first lower surface.

6. The motor according to claim 1, wherein, The first upper surface is oriented parallel to the stator axis such that the first upper surface faces the stator axis, and wherein the first lower surface is oriented parallel to the stator axis such that the first lower surface faces the stator axis.

7. The motor of claim 6, further comprising a first upper gasket disposed between the first upper surface and the first upper arm, wherein, The first upper gasket is radially compressed between the first upper surface and the first upper arm about the stator axis, and the motor further includes a first lower gasket disposed between the first lower surface and the first lower arm, wherein the first lower gasket is radially compressed between the first lower surface and the first lower arm about the stator axis.

8. The motor according to any one of the preceding claims, wherein, The second upper portion includes a second upper surface, wherein the second lower portion includes a second lower surface, wherein the second insertion portion has a second upper arm that extends toward the second upper surface and engages the second upper surface to define the second cooling channel, and wherein the second insertion portion has a second lower arm that extends toward the second lower surface and engages the second lower surface to further define the second cooling channel.

9. The motor according to claim 8, wherein, The second upper surface is oriented perpendicularly to the stator axis, such that the second upper surface faces the second direction, wherein the second lower surface is oriented parallel to the stator axis, such that the first lower surface faces the stator axis.

10. The motor of claim 8, further comprising a second upper gasket disposed between the second upper surface and the second upper arm, wherein, The second upper liner is axially compressed between the second upper surface and the second upper arm about the stator axis, and the motor further includes a second lower liner disposed between the second lower surface and the second lower arm, wherein the second lower liner is radially compressed between the second lower surface and the second lower arm about the stator axis.

11. The motor according to claim 8, wherein, The second upper surface is oriented parallel to the stator axis such that the second upper surface faces the stator axis, and wherein the second lower surface is oriented parallel to the stator axis such that the second lower surface faces the stator axis.

12. The motor of claim 11, further comprising a second upper gasket disposed between the second upper surface and the second upper arm, wherein, The second upper liner is radially compressed between the second upper surface and the second upper arm about the stator axis, and the motor further includes a second lower liner disposed between the second lower surface and the second lower arm, wherein the second lower liner is radially compressed between the second lower surface and the second lower arm about the stator axis.

13. The motor according to claim 8, wherein, The inner core includes a second lower protrusion that extends away from the interior of the stator core in the second direction, and wherein the second lower protrusion includes a second lower surface.

14. The motor according to any one of claims 1-7, wherein, The first upper portion, the second upper portion, the first lower portion, and the second lower portion are integral with each other.

15. The motor according to any one of claims 1-7, wherein, The inner core further includes a main body portion, wherein the main body portion is disposed in the stator core, and the first upper portion and the first lower portion extend from the main body portion in the first direction, and the second upper portion and the second lower portion extend from the main body portion in the second direction.

16. The motor according to any one of claims 1-7, wherein, The inner core is further defined as an overmolded core.

17. The motor according to any one of claims 1-7, wherein, The inner core is in direct contact with the plurality of windings inside the stator core, so that the stator has no fluid path that fluidly connects the first cooling channel and the second cooling channel.

18. The motor according to any one of claims 1-7, wherein, The inner core and the stator core are separate components.

19. The motor according to any one of claims 1-7, wherein, The inner core and the plurality of windings define a barrier surface perpendicular to the stator axis, wherein the barrier surface is continuous within the stator core, such that the stator has no fluid path that fluidly connects the first cooling channel and the second cooling channel.

20. The motor according to any one of claims 1-7, further comprising a rotor disposed within the stator housing and extending along a rotor axis.

21. A drive module assembly comprising a motor according to any one of claims 1-7, further comprising a gear set rotatably coupled to an output of the motor, the gear set being configured to transmit rotational torque to the wheels of a vehicle.

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