Air compressor for conveying air with a positionally reliable stator

Abstract

The invention relates to an air compressor (100) for conveying air, wherein the air compressor (100) comprises: - a stator (101), - a cooling device (103), and - a housing (105) surrounding the stator (101), wherein the cooling device (103) comprises: - a base (107), and - Multiple air guiding elements (109) are constructed on the surface of the base (107), wherein the cooling device (103) covers the winding head (111) of the stator at least on the end side in the region between the winding head (111) of the stator and the housing (105), wherein the housing (105) has multiple housing receiving portions (113, 115) through which the cooling device is mechanically coupled to the housing, wherein the stator has multiple stator receiving portions (117, 119) through which the cooling device is mechanically coupled to the stator (101), and wherein the housing (105), the air guiding elements (109), and the base (107) form an air guiding path configured to guide a mass flow of air along the stator (101).

Description

Technical Field

[0001] The invention relates to an air compressor for conveying air according to the appended claims, a method for manufacturing the air compressor, and a fuel cell system. Background Technology

[0002] Air compressors used to transport air are often designed to be particularly compact due to structural space constraints.

[0003] Due to its compact design, thermal problems arise, particularly in the stator region of the motor used to drive the air compressor. Summary of the Invention

[0004] Within the framework of the present invention, an air compressor for conveying air, a method for manufacturing the air compressor, and a fuel cell system are proposed. Further features and details of the invention are given in the corresponding dependent claims, description, and drawings. Of course, the features and details described in conjunction with the air compressor according to the invention also apply to the method for manufacturing the air compressor according to the invention or the fuel cell system according to the invention, and vice versa; therefore, the disclosures regarding various aspects of the invention can always be referred to mutually.

[0005] This invention is particularly intended to provide the possibility of robust operation for air-guided systems, especially fuel cell systems.

[0006] Therefore, according to a first aspect of the invention, an air compressor for conveying air is provided.

[0007] The proposed air compressor includes a stator, a cooling unit, and a housing surrounding the stator.

[0008] The cooling device includes a base and a plurality of air guiding elements configured on the surface of the base, wherein the cooling device covers the winding head at least on the end side in the region between the winding head of the stator and the housing, wherein the housing has a plurality of housing receiving portions through which the cooling device is mechanically coupled, wherein the stator has a plurality of stator receiving portions through which the cooling device is mechanically coupled, and wherein the housing, the air guiding elements, and the base form an air guiding path configured to guide a mass flow of air along the stator.

[0009] In the context of the invention presented herein, "end side" should be understood as the short side of the cylindrical stator.

[0010] The proposed invention is based on a cooling device arranged in the region between the winding head and the stator housing of the proposed air compressor, and covering the stator at least on its end sides. This means that the cooling device extends along the entire length, particularly on the end sides of the winding head, such that the winding head is cooled by the cooling device at least on its end sides.

[0011] Because the cooling unit is located between the winding head and the stator housing, the proposed air compressor can be designed to be particularly compact.

[0012] To cool the stator or winding heads, the cooling device, together with the casing surrounding the stator, forms an air guiding path that directs a mass flow of air via an air compressor to areas of the stator subject to particularly high heat loads, especially to the winding heads. Accordingly, heat is transferred from the stator to the mass flow of air and carried away, thus cooling the stator and enabling it to handle particularly high power loads.

[0013] The air guiding path may include multiple, especially a large number of, sub-air paths, each of which guides a sub-air mass flow to a predetermined part of the air compressor.

[0014] The proposed air compressor housing may have one or more housing receiving sections, through which the cooling device is mechanically coupled to and positioned relative to the housing. Furthermore, the housing may form the casing of the air compressor, particularly a casing with a bearing cover. Accordingly, the housing may include a bearing cover.

[0015] The stator of the proposed air compressor may have one or more stator receiving sections, through which the cooling device is mechanically coupled to the stator and positioned relative to the housing.

[0016] Accordingly, multiple housing receiving parts and multiple stator receiving parts work together to mechanically couple the cooling device with the air compressor, or to position the cooling device in the air compressor, especially for centering.

[0017] The cooling device may include, for example, a circular portion that covers the stator at one end and optionally engages with an internal region of the stator to direct mass airflow to or through the stator.

[0018] To provide an air mass flow through the air guide path, ambient air can flow into the air guide path and be guided through it by convection, or a sub-air mass flow of the main air mass flow provided by the air compressor's turbine can be guided into the air guide path, such that the stator is cooled more strongly or dynamically as the air compressor power increases. For this purpose, the cooling device may include at least one inlet opening that introduces the air mass flow into the air guide path, and at least one outlet opening that exits the air mass flow from the air guide path.

[0019] Furthermore, for example, a sub-air mass flow can be branched off downstream of the air compressor and optionally pre-cooled, so that the air compressor is dynamically and more strongly cooled, for example, as the load increases and the speed increases accordingly.

[0020] It is possible to configure multiple housing receiving portions to include raised portions that are raised relative to the base of the housing, or multiple housing receiving portions to include recessed portions that are recessed relative to the base of the housing.

[0021] In particular, the cooling device can form multiple corresponding housing receiving parts, which are connected in a form-locking manner with the multiple housing receiving parts.

[0022] The raised portion, such as a material protrusion, effectively restricts the movement space of the cooling device and pushes the cooling device into a predetermined position. For this purpose, the raised portion may extend obliquely or bend.

[0023] The housing receiving part, which is configured as a raised section, can be joined to or surround the cooling device so as to mechanically couple the cooling device with the housing.

[0024] The recesses, such as grooves, in the material of the housing effectively restrict the movement space of the cooling device and push it into a predetermined position when the cooling device is engaged in the groove. For this purpose, the recesses may extend obliquely or bendably, for example.

[0025] Alternatively, the multiple stator receiving portions may include raised portions that are raised relative to the base of the stator, or the multiple stator receiving portions may include recessed portions that are recessed relative to the base of the stator.

[0026] In particular, the cooling device can form multiple corresponding stator receiving sections, which are connected in a form-locking manner with the multiple stator receiving sections.

[0027] The raised portion, such as a material protrusion, effectively restricts the movement space of the cooling device and pushes the cooling device into a predetermined position. For this purpose, the raised portion may extend obliquely or bend.

[0028] The stator receiving section, configured as a raised section, can be joined to or surround the cooling device so as to mechanically couple the cooling device to the housing.

[0029] The recesses, such as grooves, in the stator material, for example, in the resin surrounding the stator winding heads, effectively restrict the movement space of the cooling device and push it into a predetermined position when the cooling device engages with the recess. For this purpose, the recesses may extend obliquely or bendably, for example.

[0030] It can also be configured such that multiple stator receiving sections and multiple housing receiving sections are configured to orient the cooling device relative to the longitudinal axis of the stator.

[0031] The reliable positioning of the cooling device relative to the stator ensures that the air mass flow reliably flows to the areas of the stator that are subject to particular heat loads, so that the stator can be reliably cooled and correspondingly has fail-safe or load-bearing capacity.

[0032] It can also be configured such that the cooling device covers the winding head laterally, at least partially, both on the end side and in the direction of each stator slot of the stator.

[0033] By covering the winding head at both the end and side, the surface area for transferring heat energy from the winding head to the cooling device or from the cooling device to the mass flow of air flowing along the cooling device is maximized, and the winding head is protected from mechanical loads at both the end and side.

[0034] Alternatively, the base of the cooling device can be made of a material whose thermal conductivity is higher than that of air and whose electrical conductivity is less than 1% of that of aluminum.

[0035] The high thermal conductivity of the substrate of the cooling device results in efficient heat transfer from the winding head to the cooling device, through the cooling device, and to the air mass flow along the cooling device, as well as a correspondingly good cooling effect or high cooling power.

[0036] The conductivity of the substrate is less than 10% of that of aluminum, and especially less than 1%, which suppresses eddy currents between the stator housing and the stator, thereby maximizing the power of the air compressor.

[0037] Alternatively, the base of the cooling device can be made entirely or partially of ceramic.

[0038] Ceramics, such as Al2O3 with a thermal conductivity of 20 W / mK or AlN with a thermal conductivity of 170 W / mK, have proven to be particularly advantageous for heat dissipation from the winding head and are electrically insulating.

[0039] Alternatively, an air guiding element may be constructed on the surface of the substrate, the air guiding element being made of at least one material from the following list: silicone, thermoplastic, and thermosetting plastic.

[0040] Air guiding elements or cooling devices made of silicone, thermoplastic or thermosetting plastics are electrically insulating and can be manufactured in a particularly economical and efficient manner.

[0041] Alternatively, the housing may include a base component and a bearing cover, wherein a first number of housing receiving portions are constructed in the base component, a second number of housing receiving portions are constructed in the bearing cover, and wherein the geometry of the first number of housing receiving portions is different from the geometry of the second number of housing receiving portions.

[0042] By using different housing receiving portions on the base component and the bearing cover, the cooling device can be differently shaped on the base component and the bearing cover, thereby providing a position-specific or side-specific air mass flow that extends, for example, corresponding to a specific geometry of the stator. Here, for example, the geometry of the housing receiving portion on the base component can be used to provide an input conduit for the air mass flow.

[0043] Alternatively, a first cooling device can be arranged on the first end side of the stator, and a second cooling device can be arranged on the second end side of the stator opposite to the first end side.

[0044] Two cooling devices at each end of the stator result in exceptionally high cooling power for regulating the stator temperature, allowing the stator to be subjected to exceptionally high power.

[0045] According to the second aspect, the present invention relates to a fuel cell system for energy conversion.

[0046] The proposed fuel cell system includes a fuel cell stack and a proposed air compressor configuration for supplying air to the fuel cell stack.

[0047] It is possible to configure the cooling device of the air compressor to be fluidly coupled to the cooling system of the fuel cell system.

[0048] According to a third aspect, the present invention relates to a method for manufacturing a possible configuration of the proposed air compressor.

[0049] The proposed manufacturing method includes: forming a housing, wherein the housing includes a plurality of housing receiving portions; forming a stator, wherein the stator includes a plurality of stator receiving portions; introducing the stator into the housing; and introducing a cooling device into the housing, wherein the cooling device is introduced into the housing such that the cooling device is mechanically coupled to both the plurality of stator receiving portions and the plurality of housing receiving portions.

[0050] To construct multiple housing receiving parts, the multiple housing receiving parts can be formed as integral components of the housing during the original forming process of the housing, such as during casting, or the multiple housing receiving parts can be subsequently introduced into the housing by a cutting process, such as milling, after the original forming.

[0051] To construct multiple stator receiving sections, the multiple stator receiving sections can be formed as integral components of the sheath during the original forming process of the stator, such as during the casting process of the stator sheath, or the multiple stator receiving sections can be subsequently introduced into the sheath or stator by a cutting method, such as milling, after the original forming.

[0052] The advantages described in detail in the air compressor for conveying air according to the first aspect of the invention also apply to the fuel cell system for converting energy according to the second aspect of the invention and the manufacturing method for manufacturing the possible configuration of the proposed air compressor according to the third aspect of the invention.

[0053] Other advantages, features, and details of the invention are set forth in the following description with reference to the accompanying drawings, in which embodiments of the invention are described in detail. Hereinafter, the features mentioned in the claims and the specification may be substantial to the invention individually or in any combination. Attached Figure Description

[0054] The attached diagram shows: Figure 1 A schematic diagram of one possible configuration of the proposed air compressor in a sectional side view. Figure 2 :according to Figure 1 A top view of the cooling unit arranged on the stator of the air compressor. Figure 3 One possible configuration of the proposed fuel cell system. Figure 4 : One possible configuration of the proposed manufacturing method. Detailed Implementation

[0055] exist Figure 1 An air compressor 100 for conveying air is shown. The air compressor 100 includes a stator 101, a cooling device 103, and a housing 105 surrounding the stator 101.

[0056] The cooling device 103 includes a base 107 and a plurality of air guiding elements 109 constructed on the surface of the base 107.

[0057] The cooling device 103 covers the winding head 111 of the stator 101 in the area between the winding head 111 and the cover 105.

[0058] In addition, the housing 105 includes a plurality of housing receiving parts 113, 115, through which the cooling device 103 is mechanically, and in particular firmly, coupled to the housing 105.

[0059] Furthermore, the stator 101 includes a plurality of stator receiving portions 117, 119, through which the cooling device 103 is mechanically, and in particular, firmly coupled to the stator 101. On the first side 121, the stator receiving portion 117 is configured as a raised portion or material protrusion in the sheath of the winding head 111, while the housing receiving portion 113 is configured as a groove or recess in the housing 105.

[0060] On the second side 123 opposite to the first side 121, the stator receiving portion 119 is configured as a groove or recess in the material of the winding head 111, while the cover receiving portion 115 is configured as a raised portion or a material protrusion of the cover 105.

[0061] The housing 105, together with the air guiding element 109 and the base 107, forms an air guiding path 125 that guides the mass flow of air to the winding head 111.

[0062] exist Figure 2 In the middle, a top view shows the data according to... Figure 1 The cooling device 103. Inlets 201 and 203 for the mass flow of air into the cooling device 103 can be seen here.

[0063] The air mass flow is guided by the air guide element 109 to the winding head 111 and passes through the internal portion 205 of the stator 101.

[0064] exist Figure 3 The image shows a fuel cell system 200 for converting energy.

[0065] Fuel cell system 200 includes fuel cell stack 201 and a device for supplying air to fuel cell stack 201, according to... Figure 1 100 air compressors.

[0066] exist Figure 4 The diagram shows a manufacturing method 300 for manufacturing a possible configuration of the proposed air compressor.

[0067] The manufacturing method 300 includes: a first forming step 301, in which a housing is formed such that the housing includes a plurality of housing receiving portions; and a second forming step 303, in which a stator is formed such that the stator includes a plurality of stator receiving portions.

[0068] Furthermore, the manufacturing method 300 includes: a first introduction step 305, in which a stator is introduced into a housing; and a second introduction step 307, in which a cooling device is introduced into the housing such that the cooling device is mechanically coupled or engaged to both a plurality of stator receiving portions and a plurality of housing receiving portions.

Claims

1. An air compressor (100) for conveying air. in, The air compressor (100) includes: - Stator (101) - Cooling device (103), and - A housing (105) surrounding the stator (101). The cooling device (103) includes: - Matrix (107), and - Multiple air guiding elements (109) constructed on the surface of the substrate (107). The cooling device (103) covers the winding head (111) at least on the end side in the region between the winding head (111) of the stator and the cover (105). The housing (105) has multiple housing receiving portions (113, 115), and the cooling device is mechanically coupled to the housing through the housing receiving portions. The stator has multiple stator receiving sections (117, 119), and the cooling device is mechanically coupled to the stator (101) through the stator receiving sections. The housing (105) forms an air guiding path with the air guiding element (109) and the base (107), the air guiding path being configured to guide a mass flow of air along the stator (101).

2. The air compressor (100) according to claim 1. Its features are, The plurality of housing receiving portions (113, 115) include raised portions that are raised relative to the base of the housing (105), or the plurality of housing receiving portions (113, 115) include recessed portions that are recessed relative to the base of the housing (105).

3. The air compressor (100) according to claim 1 or 2. Its features are, The plurality of stator receiving portions (117, 119) include raised portions that are raised relative to the base of the stator (101), or the plurality of stator receiving portions (117, 119) include recessed portions that are recessed relative to the base of the stator (101).

4. The air compressor (100) according to any one of the preceding claims. Its features are, The plurality of stator receiving portions (117, 119) and the plurality of housing receiving portions (113, 115) are configured to orient the cooling device (103) relative to the longitudinal axis of the stator (101).

5. The air compressor (100) according to any one of the preceding claims. Its features are, The cooling device (103) covers the winding head (111) laterally, at least partially, both at the end and in the direction of each stator slot of the stator (101).

6. The air compressor (100) according to any one of the preceding claims. Its features are, The air guiding element (109) is made of at least one material from the following list: silicone, thermoplastic and thermosetting plastic.

7. The air compressor (100) according to any one of the preceding claims. Its features are, The housing (105) includes a base component and a bearing cover. The base component has a first number of housing receiving parts (113) and the bearing cover has a second number of housing receiving parts (115), wherein the geometry of the first number of housing receiving parts (113) is different from the geometry of the second number of housing receiving parts (115).

8. The air compressor (100) according to any one of the preceding claims. Its features are, A first cooling device (103) is arranged on the first end side of the stator (101), and a second cooling device (103) is arranged on the second end side of the stator (101) opposite to the first end (115).

9. A fuel cell system (200) for converting energy. in, The fuel cell system (200) includes: - Fuel cell stack (201). - An air compressor (100) according to any one of claims 1 to 8 is used to supply air to the fuel cell stack (201).

10. A manufacturing method (300) for manufacturing an air compressor (100) according to any one of claims 1 to 8. in, The manufacturing method (300) includes: - Forming (301) a housing (105), wherein the housing (105) includes a plurality of housing receiving portions (113, 115). - Forming (303) stator (101), wherein the stator (101) includes a plurality of stator receiving portions (117, 119). - The stator (101) is introduced (305) into the housing (105), and - A cooling device (103) is introduced (307) into the housing, wherein the cooling device (103) is introduced into the housing (105) such that the cooling device (103) is mechanically coupled to both the plurality of stator receiving parts (117, 119) and the plurality of housing receiving parts (113, 115).

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