Stator assembly for an axial flux motor, in particular for a motor vehicle, and axial flux motor comprising such a stator assembly

Abstract

Stator assembly (3) for an axial flux motor (2), comprising a first chamber (33) and a second chamber (34) in fluid communication and configured to allow circulation of a cooling fluid (FR), a support plate (5) interposed between said chambers and comprising a plurality of apertures able to allow circulation of the cooling fluid (FR) and to allow passage of the coils between said chambers, and an interconnection ring (8) arranged in the first chamber (33) so as to be immersed in the cooling fluid (FR).

Description

Technical Field

[0001] This invention relates to stator assemblies for axial flux motors, and more particularly to stator assemblies for motor vehicles. The invention also relates to axial flux motors including such stator assemblies. Furthermore, the invention relates to electric or hybrid vehicles equipped with said stator assemblies and / or said motors. Finally, the invention relates to methods for assembling said stator assemblies. Background Technology

[0002] Electric or hybrid vehicles typically include at least one traction and / or propulsion motor, also known as an electric motor, that allows the vehicle to move. Knownly, an electric motor includes a rotor, which comprises a steel shaft and a composite star-shaped frame that holds at least one magnet in a rotating position near the stator. Achieving high power, particularly greater than 100 kW, involves using high-intensity current and high-speed rotor rotation. This causes the motor to easily heat up during operation, necessitating a cooling system. This requirement becomes increasingly prominent as vehicle power demands increase. Furthermore, uniform cooling must be implemented for the stator coils and the different pole shoes or teeth carrying said coils to optimize motor operation.

[0003] In axial flux motors, it is known that the stator is cooled by circulating a cooling fluid, particularly oil, at the stator coil contacts. However, to limit energy losses associated with rotor turbulence in the oil, the rotor is typically separated from the cooling fluid circulation area by a sealing diaphragm bonded to the stator and partially extending in the air gap, i.e., the space between the stator and rotor. Similarly, electrical connectors, especially interconnecting terminals or interconnecting strips involved in stator power supply, are typically arranged outside the stator volume to isolate them from the oil passages, which complicates the implementation and assembly of sealing in their respective areas.

[0004] This invention falls within this background and aims to provide an alternative to known axial flux motors, allowing for optimized thermal cooling of stator components, particularly uniform cooling among the different coils distributed within the stator. The invention also aims to simplify the assembly of the stator and the motor comprising the stator. Summary of the Invention

[0005] The present invention relates to a stator assembly for an axial flux motor, comprising a first and a second chamber in fluid communication and configured to allow circulation of cooling fluid, and a third chamber separate from the first and second chambers and configured to house a rotor.

[0006] The stator assembly also includes:

[0007] - A coil, a pole shoe carrying the coil, and a support plate supporting the pole shoe, the support plate being inserted between a first chamber and a second chamber, and including a plurality of primary orifices and a plurality of secondary orifices that allow cooling fluid circulation, the coil extending through the primary orifices;

[0008] - An interconnecting ring arranged in the first chamber for immersion in cooling fluid and connected to the coil;

[0009] - A housing connected to a support plate and defining the first and third chambers;

[0010] - Includes a partition element consisting of walls and a diaphragm, which is connected to a support plate and separates the second chamber from the third chamber.

[0011] In particular, the support plate, housing, and partition element each include openings, for example centered in the same direction, capable of accommodating at least a portion of the rotor.

[0012] In particular, stator assemblies are used in axial flux motors for motor vehicles.

[0013] Optionally, the first chamber includes a supply channel that is in fluid communication with the second chamber through a primary orifice, and a discharge channel that is separated from the supply channel and is in fluid communication with the second chamber through a secondary orifice.

[0014] Specifically:

[0015] - The discharge channel has a defined shape, particularly circular or annular, and exhibits at least one dimensional variation along said shape to allow for variations in the flow rate of the cooling fluid along said channel; and / or

[0016] - The supply channel has a defined shape, particularly circular or annular, and exhibits at least one dimensional variation along said shape to allow for variations in the flow rate of the cooling fluid along said channel.

[0017] Optionally, different primary orifices have variable cross-sections to allow variations in the flow rate of cooling fluid through different primary orifices, and / or different secondary orifices have variable cross-sections to allow variations in the flow rate of cooling fluid through different secondary orifices.

[0018] Optionally, the stator assembly also includes a protective member that extends through a plurality of primary orifices to be inserted between the coil and the edge of the orifice.

[0019] According to the example:

[0020] - The support plate is attached and secured to the housing by at least one fixing device (e.g., screws); and / or

[0021] - The partition element is attached and secured to the support plate and / or housing by at least one fixing device (e.g., screw).

[0022] Optionally, the stator assembly further includes a cooling fluid supply pipe and a fluid discharge pipe arranged in fluid communication with at least a portion of the first chamber, and an electrical connection pipe including at least one cable, the connection pipe and the supply pipe being at least partially shared, such that a portion of the at least one cable is configured to be immersed in the cooling fluid.

[0023] The present invention also relates to axial flux motors, particularly axial flux motors for motor vehicles, which include a stator assembly and a rotor according to the present invention.

[0024] Optionally, the axial flux motor includes multiple first chambers, second chambers, a support plate, a partition element, and an interconnecting ring.

[0025] The present invention also relates to electric or hybrid vehicles including stator assemblies and / or motors according to the present invention.

[0026] Finally, the present invention relates to a method for assembling an electric motor according to the present invention, comprising:

[0027] - Position the interconnecting ring on the support plate;

[0028] - Position the coil so that it is connected to the interconnecting ring and wound the coil around the pole shoe carried by the support plate through one of the primary orifices of the plurality of primary orifices;

[0029] - Position and fix the separator element to the support plate so that the pole shoe and coil are arranged in the second chamber;

[0030] - Position and secure the assembly formed by the support plate and fixing elements within the housing. Attached Figure Description

[0031] Other details, features, and advantages will become more apparent from the following detailed description, given in an indicative and non-limiting manner, and in conjunction with the various embodiments illustrated in the accompanying drawings:

[0032] Figure 1 This is a schematic view of an embodiment of a vehicle equipped with an electric motor according to the present invention.

[0033] Figure 2 This is a schematic cross-sectional view of an embodiment of a stator assembly for an electric motor.

[0034] Figure 3 This is a schematic cross-sectional view of the stator assembly support plate that carries the pole shoes.

[0035] Figure 4 This is a schematic cross-sectional view of the stator assembly support plate that carries the interconnecting rings.

[0036] Figure 5This is a schematic cross-sectional view of the stator assembly support plate that carries the pole shoes and coils.

[0037] Figure 6 It is a schematic cross-sectional view of the assembled stator assembly and the cooling fluid channels of the assembly.

[0038] Figure 7 This is a schematic top view of the stator assembly and the flow of cooling fluid circulating therein.

[0039] Figure 8 This is a schematic cross-sectional view of the motor. Detailed Implementation

[0040] Figure 1 An embodiment of a motor vehicle 1 according to the present invention is illustrated schematically. Vehicle 1 is an electric or hybrid vehicle. Furthermore, vehicle 1 can be of any type, such as a private car, commercial vehicle, truck, or bus. In particular, the vehicle 1 considered can be a connected and / or autonomous vehicle.

[0041] Vehicle 1 is equipped with an axial flux motor 2 according to the invention, also known as a traction and / or propulsion motor, comprising a stator assembly 3, the stator assembly including a plurality of pole shoes 31 (or teeth), with coils 32 wound on the pole shoes. Motor 2 also includes a rotor 4 movable relative to the stator assembly 3.

[0042] Knownly, the rotor 4 includes a shaft 41 extending along a first direction 100 through at least a portion of the stator assembly 3 and configured to be rotatably movable about a rotational axis 500 parallel to the first direction 100. Therefore, "axial flux motor" refers to a motor in which the direction of the magnetic flux generated is aligned parallel to the rotational axis 500. The rotor 4 also includes a star-shaped frame 42, particularly made of a composite material, connected to the shaft 41 and carrying a plurality of magnets 43. The different magnets 43 are arranged, in particular, in a block shape, either disc-shaped or generally disc-shaped, for rotational movement accompanying the shaft 41. The magnets 43 are arranged to extend facing the pole shoes 31 and coils 32 of the stator assembly 3, as described in more detail below, maintaining a distance from the pole shoes and coils. The space separating the rotor 4 from the pole shoes 31 and coils 32 is called the air gap.

[0043] The stator assembly 3 according to the invention generally includes at least one support plate 5 supporting the coil 32 and pole shoe 31 described above, a housing 6, and at least one partition element 7.

[0044] Furthermore, the stator assembly 3 according to the invention includes at least one first chamber 33 and at least one second chamber 34, the first and second chambers being in fluid communication with each other and configured to allow circulation of cooling fluid FR. The cooling fluid FR is configured to ensure heat treatment, particularly cooling, of the stator assembly 3, especially the coil 32 and the pole shoes 31 carrying the coil. Specifically, the cooling fluid FR is oil.

[0045] The stator assembly 3 also includes a third chamber 35, which is separate from the first chamber 33 and the second chamber 34 and configured to accommodate the rotor 4. "Separated" means that the third chamber 35 does not allow the cooling fluid FR to circulate and is not in fluid communication with the first chamber 33 or the second chamber 34. Thus, the cooling fluid FR does not circulate at the point of contact with the rotor 4.

[0046] The support plate 5 is at least partially flat or substantially flat. The support plate 5 is particularly circular or substantially circular in shape and includes a central primary opening 51 configured to accommodate the shaft 41 of the rotor 4 during motor 2 assembly. Specifically, the primary opening 51 is centered on the central axis of the stator assembly 3 and configured to be centered on the rotation axis 500 of the rotor 4. In particular, the support plate 5 is made of a metallic material, such as steel or aluminum.

[0047] The support plate 5 is arranged to be inserted between the first chamber 33 and the second chamber 34, thereby participating in defining the first chamber 33 and the second chamber 34. In this case, the first surface 50a of the support plate 5 faces the first chamber 33, while the second surface 50b of the support plate 5, which is opposite to the first surface 50a, faces the second chamber 34.

[0048] The support plate 5 carries a plurality of pole shoes 31. It is known, but not described in detail, that the pole shoes 31 are arranged in a crown shape surrounding the primary opening 51 to form stator elements. The pole shoes 31 are wound or stacked metal elements arranged and fixed to the second surface 50b of the support plate 5, for example, by adhesive bonding.

[0049] The housing 6, or outer casing, is the external structural enclosure of at least a portion of the motor 2 and the stator assembly 3. Specifically, the housing 6 is made of a metallic material, including steel and / or aluminum. The housing 6 defines the internal volume of the motor 2, including a first chamber 33, a second chamber 34, and a third chamber 35, and at least a portion of the rotor 4 extending therein. In particular, the housing 6 directly participates in defining the first chamber 33 and the third chamber 35.

[0050] According to a non-limiting embodiment, the housing 6 includes multiple sides, for example, at least partially cylindrical or generally cylindrical in shape and having a circular bottom surface. In this case, the housing 6 includes a first side 6a and a second side 6b defining the housing 6 along a first direction 100. Similarly, the housing 6 includes at least one intermediate side 6c connecting the first side 6a and the second side 6b. Optionally, but preferably, the housing 6 includes two half-housings 6e configured to form the housing 6 after assembly. The housing 6 also includes a secondary opening configured to allow the shaft 41 of the rotor 4 to pass through the stator assembly 3. In particular, the first side 6a and the second side 6b each include a central secondary opening 6d extending about the central axis or rotation axis 500 of the shaft 41 and facing the primary opening 51 of the support plate 5 when the stator assembly 3 is assembled.

[0051] Similarly, the stator assembly 3, especially the housing 6, includes at least one electrical connection tube 61 configured to receive an electrical connection cable 61a capable of supplying power to the motor 2, especially the coil 32.

[0052] Furthermore, the stator assembly 3, particularly the housing 6, includes at least one supply pipe 62 for cooling fluid FR and / or at least one discharge pipe 63, respectively configured to introduce cooling fluid FR into the motor 2 and to discharge cooling fluid FR from the motor 2. The supply pipe 62 and discharge pipe 63 are thus connected to a cooling fluid FR circuit 60 (not described in detail), which typically includes at least one heat exchanger capable of regulating the temperature of the cooling fluid FR and a pump capable of regulating the total flow rate of the cooling fluid FR. In particular, the supply pipe 62 and the electrical connection pipe 61 are adjacent to or overlap. Preferably, the connection pipe 61 and the supply pipe 63 are at least partially shared, such that a portion of the cable 61a is configured to be immersed in the cooling fluid FR, thereby allowing the cooling fluid to cool. Similarly, to limit the resulting large size problem, the discharge pipe 63 is adjacent to the supply pipe 62.

[0053] When the stator assembly 3 is assembled, the support plate 5 is connected to the housing 6 such that the first chamber 33 is located between the first side 6a and / or one of the plurality of half-housings 6e and the first side 50a of the support plate 5. The support plate 5 is therefore a removable component mounted relative to the housing 6. Optionally, but preferably, the support plate 5 is reversibly secured by at least one fastening device 64, such as a screw or screw-nut assembly.

[0054] The support plate 5 includes a plurality of primary orifices 52 and a plurality of secondary orifices 53 that allow cooling fluid FR to circulate. The orifices 52 and 53 are through-holes and extend through the thickness of the support plate between a first surface 50a and a second surface 50b. Specifically, as... Figure 6 or Figure 7As shown, the primary orifice 52 is configured to allow cooling fluid FR to enter the second chamber 34, i.e., the cooling fluid FR circulates from the first chamber 33 to the second chamber 34, while the secondary orifice 53 allows cooling fluid FR present in the second chamber 34 to exit, i.e., the cooling fluid FR circulates from the second chamber 34 to the first chamber 33. The primary orifice 52 and the secondary orifice 53 preferably have a circular shape.

[0055] Similarly, the primary orifice 52 is configured to allow the wires of the coil 32 to pass through. Therefore, when the stator assembly 3 is assembled, the coils 32 are arranged such that each extends through at least one primary orifice 52. When the motor 2 is running, the cooling fluid FR and the current supplying power to the coils 32 thus circulate simultaneously at the primary orifice 52.

[0056] The primary orifice 52 is arranged in a circular or annular shape in the support plate 5, here forming a first circle. Specifically, such a circle is centered on the central axis and / or rotation axis 500 of the rotor 4. Similarly, the secondary orifice 53 is arranged in a circular or annular shape in the support plate 5, here forming a second circle. Specifically, such a circle is centered on the central axis and / or rotation axis 500 of the rotor 4. Preferably, the primary orifice 52 is closer to the primary opening 51 than the secondary orifice 53.

[0057] Preferably, the first chamber 33 includes a supply channel 33a for cooling fluid FR and a discharge channel 33b for cooling fluid FR. The supply channel 33a is configured to direct the cooling fluid FR to the second chamber 34, while the discharge channel 33b allows the cooling fluid FR to be discharged from the second chamber 34. Preferably, the supply channel 33a and the discharge channel 33b are not in direct fluid communication within the first chamber 33. The second chamber 34 is thus inserted between the supply channel 33a and the discharge channel 33b of the first chamber 33 in the circulation direction of the cooling fluid FR, such that the cooling fluid FR flows sequentially through the supply channel 33a, the second chamber 34 (to contact the coil 32 and the pole shoe 31), and then through the discharge channel 33b.

[0058] like Figure 6 As shown in the partial diagram, the supply channel 33a and the discharge channel 33b are shown outside the stator assembly 3 for clarity, or as... Figure 7As shown, the supply channel 33a is annular in shape, centered on the central axis and / or rotation axis 500, and arranged with a primary orifice 52 forming a first circle facing it. Thus, the primary orifice 52 leads to the supply channel 33a and extends through the support plate 5 between the supply channel 33a and the second chamber 34. Similarly, the discharge channel 33b is annular in shape, centered on the central axis and / or rotation axis 500, and arranged with a secondary orifice 53 forming a second circle facing it. The secondary orifice 53 thus leads to the discharge channel 33b and extends through the support plate 5 between the discharge channel 33b and the second chamber 34. Furthermore, in the example shown, preferably, the supply channel 33a is closer to the primary opening 51 than the discharge channel 33b.

[0059] Optionally, the supply channel 33a is recessed in the housing 6, particularly in one of the plurality of sides of the housing 6, such as the first side 6a and / or the second side 6b, and / or the supply channel 33a is recessed in the support plate 5, particularly in the first side 50a. Figure 8 An embodiment is shown in which semi-channels are formed in the support plate 5 and the housing 6, the channels being configured to extend facing each other during stator assembly assembly to form a supply channel 33a. A similar principle is applied to the discharge channel 33b with necessary modifications.

[0060] Similarly, optionally, the supply pipe 62 opens at the supply channel 33a, such that the supply pipe 62 and the supply channel 33a are arranged in fluid communication, and the cooling fluid FR introduced by the supply pipe 62 circulates in the channel to be distributed to different primary orifices 52. Similarly, optionally, the discharge pipe 63 opens at the discharge channel 33b, such that the discharge channel is arranged in fluid communication, and the cooling fluid FR exiting from the discharge channel 33b through the secondary orifice 53 is subsequently sent to the discharge pipe 63.

[0061] The stator assembly 3 also includes an interconnecting ring 8, a conductive element with connector function, such as copper or aluminum, in at least a partially annular shape, capable of conducting current. Alternatively, such a conductive element may be in the shape of a curved interconnecting strip, forming an arc, and / or the stator assembly 3 may include a plurality of said arcs.

[0062] Interconnecting ring 8 is arranged in the first chamber 33 so as to be immersed in cooling fluid FR as it circulates in the stator assembly 3. Specifically, at least a portion of the portion housing the electrical connection cable 61a is also immersed in the cooling fluid in the first chamber 33. This advantageously allows for optimized thermal management of the stator assembly 3 and reduces power loss due to the Joule effect compared to prior art stators by ensuring cooling of the interconnecting ring 8 and a portion of the electrical connector. This principle allows for the use of larger currents within the motor 2, enabling the motor 2 to deliver greater power without causing component degradation.

[0063] In particular, the interconnecting ring 8 is arranged at the first surface 50a of the support plate 5, for example, in contact with and / or fixed to the first surface. Preferably, the interconnecting ring 8 is bonded to the first surface 50a of the support plate 5. Similarly, the interconnecting ring 8 is arranged near the primary aperture 52 and / or the primary opening 51. The interconnecting ring 8 thus surrounds the primary opening 51. In particular, the interconnecting ring 8 extends facing all or part of the primary aperture 52.

[0064] Therefore, the wires of the different coils 32 are connected to the interconnecting ring 8, pass through different primary orifices 52, and then wound around the pole shoes 31 of the stator elements. An electrical connection tube 61 is arranged near the interconnecting ring 8 to allow power to be supplied to the wires of the coils 32 via cables 61a and the interconnecting ring 8.

[0065] The separating element 7 is arranged on the support plate 5, especially on the second surface 50b of the support plate 5, and is configured to define the second chamber 34 and separate the second chamber 34 from the third chamber 35.

[0066] The separating element 7 includes a plurality of walls 71 and at least one diaphragm 72 connected to the walls 71. For example, the walls 71 are made of a metallic material, such as steel and / or aluminum. The separating element 7 is particularly annular or generally annular in shape, surrounding a third opening 73 that can accommodate the shaft 41 of the rotor 4. When the stator assembly 3 is assembled, the third opening 73 extends at least partially facing the primary opening 51 of the support plate 5.

[0067] Generally, the separating element 7 includes at least one inner wall 71a having a proximal position relative to the central shaft and the rotation axis 500 of the rotor 4 when the motor 2 is assembled, and at least one outer wall 71b having a distal position relative to the same axis. The at least one inner wall 71a thus defines an annular inner periphery and defines a third opening 73 of the separating element 7. The at least one inner wall 71a is therefore circular or generally circular. The at least one outer wall 71b defines an annular outer periphery and presents a second circular shape.

[0068] The separating element 7 is included on the opening side facing the support plate 5 when the stator assembly 3 is assembled. A diaphragm 72 is arranged on the side opposite the opening side, away from the support plate 5. The diaphragm 72 extends between the at least one inner wall 71a and the at least one outer wall 71b to connect the at least one inner wall and the at least one outer wall to each other. Thus, when the motor 2 is assembled, the diaphragm 72 extends on one side facing the pole shoes 31 and coils 32 of the stator elements contained in the second chamber 34, and on the other side facing at least one magnet of the rotor 4 arranged in the third chamber 35.

[0069] The separating element 7 thus forms a sealed partition between the second chamber 34 and the third chamber 35. In this way, the separating element 7 and the support plate 5 define the second chamber 34, which includes the pole shoes 31 and the coils 32, and allows the circulation of the cooling fluid FR to enable thermal management of the pole shoes 31 and the coils 32. The third chamber 35, capable of accommodating at least a portion of the rotor 4, particularly the shaft 41, the star-shaped frame 42, and the various magnets 43, is fluidly separated from the second chamber 34. Optionally, the third chamber 35 can accommodate a second fluid different from the cooling fluid FR, such as an airflow, to ensure thermal management of the rotor 4. The third chamber 35 thus optionally allows the second fluid to circulate separately from the cooling fluid FR, i.e., the cooling fluid FR and the second fluid do not mix or come into contact.

[0070] The separating element 7 is supported and fixed to the support plate 5 and / or the housing 6. In particular, the fixing is reversible and is implemented by at least one fixing device 64, such as a screw or screw-nut assembly.

[0071] Optionally, but preferably, the stator assembly 3 also includes a protective member 9 extending through a plurality of primary orifices 52 for insertion between the wires of the coil 32 and the edges of the orifices. Generally, the protective member 9 is a mounting element made of an electrically insulating material, particularly plastic, and comprises a plurality of hollow sleeves 91 configured to be inserted into different primary orifices 52 and to accommodate the wires of different coils 32, while allowing the circulation of cooling fluid FR. Thus, the protective member 9 is inserted between the wires of the powered coil 32 and the support plate 5 to prevent direct contact or excessive proximity between the coils and the support plate, and to prevent breakdown. The protective member 9 therefore has multiple functions. On the one hand, it ensures insulation; on the other hand, it ensures the guidance of the wires of the coil 32.

[0072] Figures 2 to 8 Different embodiments of the protective member 9 are shown.

[0073] like Figures 2 to 6 In the first embodiment shown, the protective member 9 includes a base 92 that carries different sleeves 91. The base 92 is, for example, an annular element disposed on the second surface 50b of the support plate 5, from which the sleeves 91 extend laterally. Each sleeve 91 then includes a first segment configured to extend through one of a plurality of primary orifices 52 into a first chamber 33, and a second segment extending into a second chamber 34. Here, "segment" means part of a whole. The first and second segments of each sleeve 91 then extend on both sides of the base 92, connected and continuously extending to each other, forming a channel that allows the cooling fluid FR and the wire of the coil 32 to pass from the first chamber 33 to the second chamber 34.

[0074] Optionally, the free end of the sleeve 91, especially the free end of the second segment of the sleeve 91, includes an inclined edge 93 to limit wear on the wire of the coil 32.

[0075] According to an alternative not shown, the base 92 may be arranged on the first surface of the support plate 5, and the above description applies with necessary modifications.

[0076] according to Figure 8 In the second embodiment shown, the protective member 9 similarly includes a base 92 and a sleeve 91 as described above. The base 92 is disposed in the first chamber 33, specifically connected to the first surface 50a of the interconnecting ring 8 and / or the support plate 5. Optionally, the base 92 is configured to receive at least a portion of the interconnecting ring 8 and / or the electrical connection cable 61a. The base 92 has an annular shape to support different sleeves 91. The sleeves 91 extend through different primary orifices 52, as described above, except that the sleeves include a single segment extending into the second chamber 34. Optionally, the free end of the sleeve 91 includes a beveled edge 93.

[0077] Optionally, the stator assembly 3 is configured to allow the flow rate of the cooling fluid FR to vary according to the region of the stator, in order to optimize the uniformity of cooling of the different pole shoes 31 and coils 32. This principle is specifically designed to regulate the flow rate of the cooling fluid FR circulating to the different coils 32 in the different primary orifices 52 and / or secondary orifices 53 to compensate for pressure losses and to approach or achieve uniform cooling of the different components.

[0078] According to the first embodiment, the annular shape of the discharge channel 33b and / or the annular shape of the supply channel 33a varies by at least one dimension along said annular shape to allow for variations in the flow rate of the cooling fluid FR within the second chamber 34 and / or within the annular shape under consideration. For example, the variation in dimension is defined by the width of the channel under consideration along a radial axis derived from the rotation axis 500 of the rotor 4. In particular, the variation in dimension, in the case of the supply channel 33a, depends on the position of a portion of the channel under consideration relative to the supply pipe 62, or in the case of the discharge channel 33b, depends on its position relative to the discharge pipe 63. In practice, the flow rate of the cooling fluid tends to be naturally higher, for example, near the supply pipe 62, and implementing a flow rate variation within at least one channel advantageously allows for limiting or even compensating for this phenomenon.

[0079] Alternatively or additionally, the different primary orifices 52 may have variable-sized circular cross-sections to allow variations in the flow rate of the cooling fluid FR through the different primary orifices 52, and / or the different secondary orifices 53 may have variable-sized circular cross-sections to allow variations in the flow rate of the cooling fluid FR through the different secondary orifices 53. For example, the different primary orifices 52 may have variable-sized circular cross-sections depending on their position or angular sector within the annular shape including the primary orifices 52. In particular, this variation is implemented relative to the position of the supply pipe 62 of the cooling fluid FR. Similarly, alternatively, the different secondary orifices 53 may have variable-sized circular cross-sections depending on their position or angular sector within the annular shape including the secondary orifices 53, particularly relative to the position of the discharge pipe 63 of the cooling fluid FR.

[0080] When the primary orifice 52 is optionally traversed by the protective member 9 as described above, variations in the cross-section of different primary orifices 52 can be optionally implemented by variations in the cross-section of different sleeves 91 of the protective member 9, the cross-section variation depending on the position of the primary orifice 52 traversed by the sleeves 91 within the annular shape including the orifice. The protective member 9 thus includes a plurality of sleeves 91 with variable cross-sectional dimensions to allow the flow rate of the cooling fluid FR to vary according to the stator assembly region traversed, thereby optimizing the uniformity of cooling of the different pole shoes 31 and coils 32.

[0081] In particular, such as Figure 8 As shown, the stator assembly 3 according to the present invention includes a plurality of first chambers 33, second chambers 34, a support plate 5, a partition element 7, and an interconnecting ring 8 arranged within a housing 6. Optionally, the stator assembly 3 includes a plurality of protective members 9, a supply pipe 62, a discharge pipe 63, and an electrical connection pipe 61. In practice, the stator assembly 3 may be symmetrical with respect to the intermediate plane 250 of the motor 2 passing through the first chambers 33 and / or through the star frame 42 of the rotor 4 and the magnet 43.

[0082] Therefore, for clarity, the aforementioned components are referred to as the first stator subassembly 3a, which includes a first first chamber 33', a first second chamber 34', a first support plate 5', a first partition element 7', and a first interconnecting ring 8'. The stator assembly 3 according to the invention may then include a second stator subassembly 3b arranged symmetrically with respect to the intermediate plane 250 and the first subassembly 3a, particularly including a second first chamber 33'', a second second chamber 34'', a second support plate 5'', a second partition element 7'', and a second interconnecting ring 8''. The third chamber 35, in which the rotor 4 extends, thus extends between the first subassembly 3a and the second subassembly 3b, i.e., between the first second chamber 34'' and the second second chamber 34''. Similarly, the first protective member 9' is configured to mate with the first support plate 5', while the second protective member 9'' is capable of mate with the second support plate 5''.

[0083] Alternatively, the stator assembly 3 includes a first supply pipe 62' arranged in fluid communication with a first first chamber 33', and a second supply pipe 62'' in fluid communication with a second first chamber 33'', particularly in fluid communication with the respective supply passage 33a of the chambers. The same applies to the first discharge pipe 63' and the second discharge pipe 63'' arranged in fluid communication with the first and second first chambers 33'', respectively, particularly in fluid communication with the respective discharge passage 33b of the chambers. Alternatively, the stator assembly 3 includes a supply pipe 62 shared with the first and second first chambers 33'' and / or a discharge pipe 63 shared with the first and second first chambers 33''.

[0084] Similarly, each stator subassembly 3a, 3b, and especially each second chamber 34', 34'', includes a subassembly of the pole shoe 31 and coil 32 as described above. The stator assembly 3 then includes one or more electrical connection tubes 61 capable of supplying power to the different coils 32.

[0085] Therefore, when the motor 2 is assembled and running within the vehicle 1, the cooling fluid FR circulates in a cooling fluid circuit 60 arranged to be in fluid communication with the motor 2, and particularly with the first sub-assembly 3a and the second stator sub-assembly 3b. The cooling fluid FR is guided through the at least one supply pipe 62 to the first chambers 33', 33'' of each sub-assembly, particularly the supply passages 33a of the first and second chambers 33''. The interconnecting rings 8 of each stator sub-assembly 3a, 3b are then immersed in the cooling fluid FR, which is able to capture the heat of the interconnecting rings to allow them to be cooled.

[0086] The cooling fluid FR is then distributed through the primary orifice 52 into the second chambers 34 of the different stator sub-assemblies 3a, 3b. As the cooling fluid FR circulates in the second chambers 34, it traps heat from the wires of the different coils 32, allowing the coil wires to cool. The cooling fluid FR thus moves from the central region of the stator assembly 3, i.e., the region near the primary opening 51 of the support plate 5, towards the peripheral region distal to said primary opening 51. The cooling fluid FR is then discharged from the second chambers 34 into the first chamber 33 through the secondary orifice 53, specifically into the discharge channel 33b of the first chamber 33. The cooling fluid FR is then returned to the cooling circuit through the discharge pipe 63.

[0087] Simultaneously, current is guided through cable 61a arranged in connecting tube 61 to the wire of coil 32 connected to interconnecting ring 8 at first chamber 33. The current circulates along wire 32, passes through primary orifice 52, simultaneously with cooling fluid FR, and then circulates around the winding of the wire around different pole shoes 31. The current, i.e., the electron flow, and the cooling fluid FR flow thus circulate in the first chamber 33 and second chamber 34 of the different stator subassemblies 3a, 3b.

[0088] Simultaneously, the rotor 4, arranged in the third chamber 35, pivots about the rotation axis 500. Optionally, as described above, the second fluid can then circulate in the third chamber 35, while the cooling fluid FR circulates in the first chamber 33 and the second chamber 34 of each stator sub-assembly 3. The second fluid is then introduced by the second circuit and separated from the cooling fluid FR, such that within the motor 2, the cooling fluid FR and the second fluid do not come into direct contact or mix.

[0089] It should be noted that the present invention can be extended to motor assemblies comprising multiple stator assemblies 3, wherein the multiple stator assemblies 3 include a common rotor 4 shaft 41 or different rotor 4 shafts 41.

[0090] The invention extends to a method of assembling a motor 2 according to the invention, which first includes positioning an interconnecting ring 8 on a support plate 5. Then, the wires of the coil 32 are positioned. These wires, connected to the interconnecting ring 8, are pulled out to pass through at least one primary aperture 52 and wound around the pole shoe 31 carried by the support plate 5. A separator element 7 is then positioned and secured to the support plate 5, for example by a securing device 64, such that the pole shoe 31 and the coil 32 are arranged in a second chamber 34 defined by the separator element 7 and the support plate 5. Optionally, when the stator assembly 3 includes at least one protective member 9, the protective member 9 may be arranged on the support plate 5 before or simultaneously with the positioning of the separator element 7.

[0091] Finally, the method involves positioning and securing the assembly formed by the support plate 5 and the partition element 7 within the housing 6, particularly within one of the plurality of half-housings 6e. The rotor 4 is then arranged in the third chamber 35 of the motor 2, and the housing 6 can be closed, for example by securing the half-housings 6e to each other.

[0092] It should be understood that when the stator assembly 3 and the motor 2 according to the present invention include a plurality of stator sub-assemblies as described above, the above steps are applied to each stator sub-assembly under consideration.

[0093] The present invention therefore proposes a stator assembly and motor comprising multiple chambers that allow for cooling fluid circulation and thermal management of the moving elements (especially coils) and electrical connectors (especially interconnecting rings) of the stator assembly. The proposed solution advantageously allows for optimized thermal management of the motor, thereby enabling the use of more powerful currents within the motor because the interconnecting rings and portions of the cable 61a forming the connector elements are immersed in the cooling fluid. The method also allows for simplification of the motor and reduction of motor costs, as the need for a sealed storage area for the electrical connectors to isolate the motor from the cooling fluid circulation is eliminated. This principle also allows for simplified motor assembly. Furthermore, the invention can be extended to a wide range of axial flux motors.

[0094] However, the invention is not limited to the modes and configurations described and shown herein, and extends to any equivalent modes or configurations and any technically feasible combinations thereof, provided that the modes and configurations ultimately achieve the functions described and shown herein.

Claims

1. A stator assembly (3) for an axial flux motor (2), comprising a first chamber (33) and a second chamber (34) in fluid communication and configured to allow circulation of cooling fluid (FR), and a third chamber (35) separated from the first chamber (33) and the second chamber (34) and configured to accommodate a rotor (4), the stator assembly (3) further comprising: - A coil (32), a pole piece (31) carrying the coil (32), and a support plate (5) supporting the pole piece (31), the support plate being inserted between the first chamber (33) and the second chamber (34), and including a plurality of primary orifices (52) and a plurality of secondary orifices (53) that allow cooling fluid (FR) circulation, the coil (32) extending through the primary orifices (52); - An interconnecting ring (8) arranged in the first chamber (33) for immersion in cooling fluid (FR) and connected to the coil (32); - A housing (6) connected to the support plate (5) and defining the first chamber (33) and the third chamber (35); - A separating element (7) including a wall (71) and a diaphragm (72), the separating element being connected to the support plate (5) and separating the second chamber (34) from the third chamber (35).

2. The stator assembly (3) according to claim 1, wherein, The first chamber (33) includes a supply channel (33a) that is in fluid communication with the second chamber (34) through the primary orifice (52) and a discharge channel (33b) that is separate from the supply channel (33a) and in fluid communication with the second chamber (34) through the secondary orifice (53).

3. The stator assembly (3) according to claim 2, wherein: - The discharge channel (33b) has a defined shape, particularly circular or annular, and varies by at least one dimension along said shape to allow variations in the flow rate of the cooling fluid (FR) along the discharge channel; and / or - The supply channel (33a) has a defined shape, particularly circular or annular, and varies by at least one dimension along the shape to allow the flow rate of cooling fluid (FR) along the supply channel to vary.

4. The stator assembly (3) according to any one of claims 1 to 3, wherein, Different primary orifices (52) have cross-sections with varying dimensions to allow for variations in the flow rate of cooling fluid (FR) through the different primary orifices (52), and / or different secondary orifices (53) have cross-sections with varying dimensions to allow for variations in the flow rate of cooling fluid (FR) through the different secondary orifices (53).

5. The stator assembly (3) according to any one of claims 1 to 4, wherein, The stator assembly also includes a protective member (9) extending through the plurality of primary orifices (52) for insertion between the coil (32) and the edge of the primary orifice.

6. The stator assembly (3) according to any one of claims 1 to 5, wherein: - The support plate (5) is attached to and fixed to the housing (6) by at least one fixing device (64), such as a screw; and / or - The separating element (7) is attached and fixed to the support plate (5) and / or the housing (6) by at least one fixing device (64), such as a screw.

7. The stator assembly (3) according to any one of claims 1 to 6, wherein, The stator assembly further includes: a supply pipe (62) and a discharge pipe (63) of cooling fluid (FR) arranged in fluid communication with at least a portion of the first chamber (33); and an electrical connection pipe (61) including at least one cable (61a), the electrical connection pipe (61) and the supply pipe (63) being at least partially shared, such that a portion of the at least one cable (61a) is configured to be immersed in the cooling fluid (FR).

8. An axial flux motor (2) comprising a stator assembly (3) and a rotor (4) according to any one of claims 1 to 7.

9. An electric or hybrid vehicle (1) comprising a stator assembly (3) according to any one of claims 1 to 7 and / or an axial flux motor (2) according to claim 8.

10. The assembly method of the axial flux motor (2) according to claim 8, comprising: - Position the interconnecting ring (8) on the support plate (5); - Position the coil (32) so that the coil is connected to the interconnecting ring (8) and the coil is wound around the pole shoe carried by the support plate (5) through one of the primary orifices (52) of the support plate (5); - Position and fix the separating element (7) on the support plate (5) so that the pole shoe (31) and the coil (32) are arranged in the second chamber; - Position and fix the assembly formed by the support plate (5) and the fixing element in the housing (6).

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