Electric motor with enhanced thermal characteristics

Abstract

To provide an electric motor with enhanced thermal characteristics which enhances heat transmission from windings, reduces the temperature of the windings, prevents damage to a motor, and enables an increase of current limit.SOLUTION: An example stator of an electric motor includes a lamination stack comprising a plurality of segments disposed adjacent to each other in a radial array; a slot formed in one of the plurality of segments of the lamination stack; a slot liner disposed in the slot and configured to be electrically insulating; a thermally conductive gap filler disposed in a gap between the slot liner and the segment; and windings disposed in the slot.SELECTED DRAWING: Figure 10

Description

[Technical field]

[0001] This application is a continuation of U.S. Provisional Application No. 62 / 909,850, filed October 3, 2019. Priority is claimed, which is incorporated herein by reference in its entirety.

[0002] The present disclosure generally relates to an electric motor having improved thermal properties and improved heat transfer to the electric motor's surrounding environment. The present invention relates to systems and assemblies that include a motor. [Background technology]

[0003] An electric motor is an electric machine that converts electrical energy into mechanical energy. A magnetic motor works by the interaction of the magnetic field in the motor with the current in the windings, which causes the shaft to rotate. Electric motors generate power in the form of direct current (DC) from a battery, automobile, or rectifier. ) power source, or an alternating current (AC) source such as a power grid, inverter, or generator. Can be provided.

[0004] The torque and power produced on the shaft of the motor is determined by the current or current introduced through the windings. is limited by the amount of power. If the current increases beyond a certain limit, the temperature of the windings will rise. This can cause the wires and electric motors to rise and damage the wires and electric motors.

[0005] It is therefore possible to enhance the heat transfer from the windings and thereby increase the temperature of the windings for a given current input. The thermal characteristics are designed to reduce the temperature, prevent damage to the motor, and allow for increased current limiting. It may be desirable to have an improved electric motor. It is with this in mind that the disclosure made herein is presented. Summary of the Invention

[0006] The present disclosure describes implementations related to electric motors with improved thermal characteristics.

[0007] In a first exemplary implementation, the present disclosure describes a stator for an electric motor. (i) a lamination stack; and (ii) a slot formed in the lamination stack. and (iii) a slot line disposed in the slot and configured to be electrically insulating. and (iv) a gap between the slot liner and the lamination stack. a thermally conductive gap filler; and (v) a winding disposed in the slot.

[0008] In a second exemplary implementation, the present disclosure describes an assembly for an electric motor. The bridge includes a stator having an open annular space. The stator is arranged adjacent to each other in a radial array. (ii) a lamination stack having a plurality of segments disposed in contact with each other; A plurality of slots formed between adjacent segments of a plurality of segments of a motion stack and (iii) a plurality of slots, each of which is configured to be electrically insulating. (iv) each slot liner and lamination stack; a thermally conductive gap filler disposed in each gap between the plurality of segments; and (v) a winding disposed in the plurality of slots. The assembly further comprises a stator opening. The steel core is placed in an annular space, and the steel core is surrounded by a radial array of 1000 .mu.m. and a plurality of magnets attached to the rotor.

[0009] In a third exemplary implementation, the present disclosure describes a method, the method including: (i) controlling a power supply of an electric motor; Providing a segment of a stator lamination stack, the lamination (ii) forming a slot in the stack segment from an electrically insulating material; (iii) providing a thermally conductive slot liner on an outer surface of the slot liner; (iv) adding a thermally conductive gap filler to the slot liner; A slot with thermally conductive gap filler material applied to it is placed between the outer surface and the segment. inserting a slot of the lamination stack segment into the slot of the lamination stack segment; ) A slot liner and thermally conductive gap filler are placed between the wire and the segment. and winding a wire around the segment so that the wire is spaced apart from the segment.

[0010] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, implementations, and features, further aspects, implementations, and features are illustrated in the drawings and the accompanying drawings. and the following detailed description. Effect of the Invention

[0011] The novel features believed to be characteristic of the illustrative examples are set forth in the appended claims. However, illustrative examples, as well as preferred modes of use, further objects and The following detailed description of illustrative examples of the present disclosure when read in conjunction with the accompanying drawings, which are incorporated herein by reference in their entirety. This will be best understood by reference to. [Brief description of the drawings]

[0012] [Figure 1] FIG. 1 is a perspective view of an electric motor according to an exemplary implementation. [Diagram 2] FIG. 2 is a perspective view of a stator and a rotor mounted within the stator, according to an example implementation. [Diagram 3]FIG. 3 is a perspective view of a stator lamination stack according to an exemplary implementation. [Figure 4] FIG. 4 is an exploded view of insulating slot liners disposed in respective slots of a lamination stack according to an example implementation. [Diagram 5] FIG. 5 is a perspective view of an individual slot liner according to an example implementation. [Figure 6] FIG. 6 is a diagram illustrating components associated with a segment of a lamination stack prior to assembly and winding of stator wires, according to an example implementation. [Figure 7] FIG. 7 illustrates a segment of a lamination stack after components have been assembled and wire wound, according to an exemplary implementation. [Figure 8] FIG. 8 is a partial cross-sectional view of a segment of a lamination stack, according to an example implementation. [Figure 9] FIG. 9 is a diagram illustrating the placement of thermally conductive gap fillers in the gaps between the slot liners and the segments of the lamination stack, and between the cooling tubes and the segments of the lamination stack, according to an exemplary implementation. [Figure 10] FIG. 10 illustrates an exemplary implementation of disposing thermally conductive gap fillers across the interfaces between the slot liners and the segments of the lamination stack, and between the cooling tubes and the segments of the lamination stack. [Figure 11] FIG. 11 is a flowchart of a method for assembling a stator or electric motor, according to an example implementation. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] The torque and power generated at the shaft of an electric motor is conducted through the windings of the electric motor. It can be limited by the amount of current or power input. If the current is increased beyond a certain limit, , which could damage the wires and motor.

[0014] Among other examples, disclosed herein are electric motors with improved thermal and heat transfer characteristics. In particular, the disclosed system includes a winding insulation lanyard. Using thermally conductive gap filler between the insulator and the lamination stack of an electric motor The thermally conductive gap filler is adapted to fit the cooling tubes of the electric motor and the cooling tubes disposed in the gap filler. A thermally conductive gap filler may also be placed between the lamination stack channel. The agent can improve heat transfer from the windings of the electric motor.

[0015] Improved heat transfer allows the current limit of the electric motor to be increased, so the same electric motor The motor can produce more torque and power at a given torque due to improved heat transfer. This allows the electric motor to operate at a lower temperature relative to the torque output, , improving the efficiency of electric motors.

[0016] FIG. 1 illustrates a perspective view of an electric motor 100 in accordance with an exemplary embodiment. 0 includes a stator 102. The stator 102 is configured to generate a magnetic field. In particular, As described below, the stator 102 is wrapped around the lamination stack. The stator 102 may include windings that generate a magnetic field when a current is applied to the windings. Also, the attachment of the electric motor 100 to a machine or device that utilizes the electric motor 100 The device may include a mounting location 103 to enable

[0017] The electric motor 100 further includes a rotor 104. The stator 102 is arranged with the rotor 104. The rotor 104 may have an open annular space in which a rotor is placed. To achieve this, magnets are provided that can interact with the magnetic field generated by the stator 102. The rotor 104 may be attached to the stator 102 via bearings 106, for example. The mounting allows it to rotate relative to the stator 102 .

[0018] The shaft 108 may be coupled to the rotor 104. The shaft 108 may be coupled to the rotor 104. 04 to transmit the torque generated by, for example, a gearbox or a machine component The electric motor 100 is configured to generate a The electric motor is then fed to a machine that utilizes the torque generated and the resulting rotational motion of the shaft 108. To further facilitate mounting of the controller 100, an alternative mounting location 109 may be included. .

[0019] The electric motor 100 transmits sensor information indicating the position of the rotor 104 to the electric motor 100. Other devices such as feedback devices 110 (e.g., sensors) that provide The electronic controller then controls the stator 102 at the appropriate time. The windings can be energized to achieve the desired torque.

[0020] A cable 112 may be used to supply current to the windings of the stator 102. The cable 112 also transmits the electrical signal generated by the feedback device 110. , which can be used to indicate the position of the rotor 104 to the amplifier.

[0021] FIG. 2 illustrates a stator 102 and a rotor mounted within the stator 102, in accordance with an exemplary embodiment. 1 shows a perspective view of the rotor 104 assembly 200. The stator 102 has a steel core. The stator 102 may include a lamination stack. The assembly stack can be fabricated as a single part (e.g., a one-piece structure) or as shown in FIG. As will be explained below, multiple segments may also be provided.

[0022] The wires are wound on segments of the lamination stack. For example, Figure 2 shows a stator Individual coils (bundles of wire) such as coil 201 are shown wound on segments 102 . The coils are separated from each other to prevent electrical short circuits from occurring. When energized, the coil acts as an electromagnet and can generate a magnetic field.

[0023] The rotor 104 may also have a steel core. 104 steel core. There may be multiple magnets (eg, permanent magnets).

[0024] The current provided to the coils of the stator 102 is determined in a specific sequence. In this way, the coils of the stator can be provided with a The magnetic field generated by the stator 102 effectively moves or changes in a circular fashion around the stator 102. The magnetic field interacts with the magnets of the rotor 104, and such interaction between the magnetic field and the magnets This action causes the rotor 104 (and the shaft 108 coupled thereto) to rotate.

[0025] FIG. 3 is a perspective view of a lamination stack 300 of the stator 102, according to an exemplary implementation. As shown in FIG. 3, the lamination stack 300 is generally donut shaped. and has an open annular space 302 in which the rotor 104 can be placed. The stack 300 includes laminated magnetic steel sheets. The laminations are formed so that the composite material is to achieve the specified strength, stability, acoustic insulation, appearance, or other desired electrical properties. , is a technique / process for producing materials in multiple layers.

[0026] The lamination stack 300 comprises a steel with added silicon, also known as electrical steel. The material is silicon steel, known as ferroelectric. Adding silicon to steel increases its electrical resistance and Improved ability to penetrate steel and reduced hysteresis loss in steel. Lamination Stack 300 represents the core of the stator 102, and when the current is modulated by the windings of the stator 102 laminated and insulated to reduce induced circulating currents and associated heat. can be.

[0027] In the example, the lamination stack 300 may be a single piece that is not segmented or For example, the lamination stack 300 may be The wire may have teeth similar to a gear and receive the wire through slots or spaces between the teeth. The device can be configured to include

[0028] In another example, the lamination stack 300 includes segments 304, 306. , and a plurality of segments, such as segment 308, arranged in a radial array Segments are generally arranged adjacent to each other with C-shaped edges on either side. The beam is formed or shaped as an I-beam with a channel or slot. When two adjacent segments meet each other, a slot is formed between them, adjacent segments of the C-shaped channel or respective slot. For example, , a slot 310 is formed between the segment 304 and the segment 306, and the slot 312 is formed between segment 306 and segment 308. Although reference is made to a multi-segment structure of termination stack 300, a similar description would be applicable to a single Laminations made as a single, unsegmented component with one structure It should be understood that such components are applied to the stack. Holes, similar to slots 310, 312 formed therein for receiving the chuck liners, The signal may have a channel or a slot.

[0029] Each of the slots 310, 312 corresponds to one segment of the lamination stack 300. One slot (partial slot) formed in the lamination stack 300 and a second slot (partial slot) formed in the adjacent segment. The term "slot" is used herein to refer to a complete slot, such as slot 310 or slot 312. It is used to refer to a slot, an individual slot in a segment of a lamination stack, or It is also used to refer to a partial slot (C-shaped channel). The wire is The lamination stack 300 of wire bundles or coils such as the coil 201 to be It is wrapped around a rod.

[0030] When a current is applied to the wire, the temperature of the wire increases and heat is generated. The heat is caused by winding losses and The temperature rise in the wire can cause damage as explained below. This can limit the performance of the electric motor 100.

[0031] In the example, a lamination stack 300 and a wire disposed therein are cooled. To achieve this, the lamination stack 300 can be liquid cooled. As shown in FIG. Each of the segments may have a channel disposed therein that is semicircular in shape. For example, the segment 304 may have a longitudinally extending circumferential surface that is parallel to the periphery of the segment 304. The tube is disposed through the semicircular channel 314. A cooling fluid can be provided through such a tube, This absorbs some of the heat generated by the wire and reduces the heat generated by the lamination stack 300. and cooling the wire disposed therein.

[0032] The coils of the stator 102 are individually energized as described above to produce a moving or changing magnetic field. Therefore, the coil wire is electrically isolated from the lamination stack 300. It is desirable to prevent short circuits or electrical connections between the wires of two adjacent coils. To isolate the wires from the segments of the lamination stack 300, an insulating liner is provided. is placed in a slot in the lamination stack 300 to act as an electrical insulator. For example, a paper liner can be used as an insulating liner.

[0033] FIG. 4 illustrates an exemplary implementation of the lamination stack 300 in each slot. FIG. 5 shows an exploded view of the insulating slot liners in place, with FIG. The slots in the lamination stack 300 are shown in a radial array in FIG. Each insulating paper slot liner can be received therein. For example, , an insulating paper slot liner 400 can be inserted into the slot 310, and the insulating paper slot A liner 402 can be inserted into the slot 312. In the example, an insulating paper slot liner can be constructed with two separate slot liners, Each slot liner may have a U-shape or a C-shape so that they When they meet at their facing edges, a slot or channel is formed between them through which The wires of the coils of the stator 102 are laid out.

[0034] FIG. 5 shows an example of such a slot liner 500. The slot liner 500 is a first a first side portion 502, a second side portion 504, and a second side portion 502 joined to the second side portion 504 With this configuration, the slot liner 500 can have a connecting portion 506 that connects the slot liner 500 to the slot liner 502. forms a channel therein (eg, a C-shaped channel).

[0035] Two slot liners similar to the slot liner 500 are attached to the side of the slot liner. so that the edges of each are in contact with each other (i.e., the joints are not in contact with each other, but rather rather, they are arranged opposite each other, with the C channels located between them. The insulating paper slot liner shown in FIG. 4 is formed. The slot liner (e.g., slot liner 500) is a lamination stack 3 00 can be inserted individually into each segment slot.

[0036] In another example, the insulating paper slot liners 400, 402 are two separate slot liners. In yet another example, the insulating paper Rather than having separate insulating paper slot liners such as slot liners 400, 402 , the slot liner of the entire lamination stack 300 is rotated around the lamination stack. The blocks 300 may be fabricated as a single component that lines each slot. .

[0037] FIG. 6 illustrates the stator 102 prior to assembly and wire winding, according to an exemplary implementation. The components associated with a segment 600 of the lamination stack 300 are shown. Segment 600 may be any of the segments of lamination stack 300 (e.g., The segment may represent any of the segments 304, 306, or 308.

[0038] As mentioned above, the segments of the lamination stack 300 generally have a The segment 600 is formed or shaped as an I-beam with a C-shaped channel. A first slot or a first channel 602 and a second slot or a second channel 603 04. The first slot liner 606 may be disposed in the first channel 602. Similarly, a second slot liner 608 can be disposed in the second channel 604. The slot liners 606, 608 may also be arranged to define the channel of the segment 600. The wires can be C-shaped to fit the shape of the panels 602, 604. When wrapped around the wire 600, the slot liners 606, 608 hold the wire in the segments. 6. The insulating layer 604 is insulated from the sides of the channel 600 (i.e., the surfaces of the channels 602, 604).

[0039] The slot liners 606, 608 do not extend to the ends of the segment 600, and the wires are The wire wraps around the end of segment 600, removing the end face of segment 600 from the end turn of the wire. To insulate the end turns of the wire, a first end-turn insulator is used. A flange 610 can be inserted into the first end of the segment 600 prior to winding the wire. A second end turn insulator 612 may be inserted into the second end of the segment 600. Cut.

[0040] FIG. 7 shows a cell after assembling its components and wrapping wire 700, according to an exemplary implementation. As shown in FIG. 7, a slot liner such as a slot liner 606 is shown. The insulator is disposed in each channel of the segment 600 and has an end turn insulator 610. , 612 are also inserted into each end of the segment 600. Next, the wire 700 600 around the segment 600 to form a coil associated with the segment 600. It can be achieved.

[0041] With this configuration, the wire 700 is electrically isolated from the segment 600, but Thus, multiple segments of the lamination stack 300 are assembled into a radial array. When forming the lamination stack 300, the respective coils are aligned with each other. The wire is then electrically insulated from an electrically insulating material (e.g., nylon polyamide). The individual wires in a given segment are coated with a synthetic polymer such as ethylene glycol to separate them from each other. This allows for separation and prevents electrical shorts.

[0042] When inserted into the channels 602, 604, the outer surfaces of the slot liners 606, 608 However, the inner surface of the segment 600 of the termination stack 300 may be in contact with the inner surface of the segment 600. However, the gap is formed between the outer surfaces of the slot liners 606 and 608 and the inner surface of the segment 600. can be separated.

[0043] FIG. 8 illustrates a partial cross-sectional view of a segment 600, according to an exemplary implementation. Thus, when the slot liner 606 is inserted into the channel 602 of the segment 600, The gap 800 is formed by the side portions (e.g., side portions 502, 504) and the connecting portions (e.g., , the outer surface of the connection portion 506) of the segment 600 in which the slot liner 606 is disposed It may be separated from the inner surface of the channel 602 .

[0044] As discussed above with respect to FIG. 3, each of the segments of the lamination stack 300 The cooling tube may have a semicircular channel disposed therein for receiving the cooling tube. For example, segment 600 may receive cooling tubes 802 as shown in FIG. Another gap 804 can be inserted between the semiconductor chip where the cooling tube 802 is located. By separating the cooling tubes 802 from the inner surface of the segment 600 that bounds the circular channel This can be done.

[0045] When electrical current is provided through wires (e.g., wires 700) of electric motor 100, Heat may be generated, causing the temperature of the components of the electric motor 100 to increase. The heat generated by the wire or coil of 00 can be called winding losses and is due to the current in the wire. It can be determined based on the magnitude of the winding losses (I) and electrical resistance (R). I 2 It can be determined as R.

[0046] In addition, the generated heat (winding loss) depends on the temperature of the wire (Tw), the ambient temperature (Ta), and The electric motor is designed with a specific heat transfer coefficient (q) based on the thermal resistance from the windings to the ambient (Rthwa). 100 to the surrounding environment. In particular, the heat transfer is expressed by the following equation:

[0047]

number

[0048] can be determined by:

[0049] For a given ambient temperature Ta, electrical resistance R, and thermal resistance Rthwa from the winding to ambient Equation (1) states that the winding temperature Tw is proportional to the square of the current (I 2 ) is proportional to the electric motor 1 During operation of the electric motor 100, if the winding temperature Tw exceeds a threshold level, damage to the electric motor 100 may occur. For example, the coating of the wire (e.g. polyamide coating) This can damage the coil or winding, causing the individual wires in the coil or winding to break apart. may come into contact with the

[0050] To prevent damage to the electric motor 100, the magnitude of the current (I) should be such that winding losses are at a certain level. Above this threshold, the winding temperature Tw is limited to prevent it from exceeding a threshold level. While limiting the magnitude of the current (I) that the electric motor 100 can generate, In particular, the amount of torque that the electric motor 100 can generate can be limited. Luk(T) is T=K t I can be determined as, where K tis the motor torque constant is a number based on a constant multiplied by the length of the stator 102 and the number of turns of wire. The power (P) generated by the electric motor 100 is given by P=Tω=K t Determine as Iω where ω is the rotation of the rotor 104 or the shaft 108 coupled thereto. It's speed.

[0051] Therefore, limiting the magnitude of the current I also limits the amount of current that the electric motor 100 can generate. It also limits the torque T and power P that can be generated. The quantity is determined by the efficiency of the electric motor 100 (e.g., the power P generated by the electric motor 100). divided by the power provided to the electric motor 100. By operating the electric motor 100 at a lower winding temperature Tw for a given power output P, The efficiency of the motor 100 can be increased.

[0052] The slot liners discussed above (e.g., slot liners 500, 606, 608) , may be constructed to be electrically insulating but not thermally conductive, and therefore This can cause a higher thermal resistance to the environment and hinder the transfer of heat from the wire to the environment. In other words, throttles that are not constructed to be made of thermally conductive material In addition, the slot liner and laminations may increase Rthwa. If there is a gap between segments of the stack (for example, gap 800), The cap may be filled with air, which may further increase Rthwa.

[0053] Electric motor 100 can receive a larger current (I) without damaging its components. One technique that allows this to be achieved is to reduce the thermal resistance from the winding to ambient (Rthwa). Based on the above formula (1), by reducing Rthwa, For a given current (I), the winding temperature Tw can be maintained at a specific level, As a result, the electric motor 100 is capable of producing higher torque (T) and torque without damaging its components. Alternatively, the same current level (I) can be used. The electric motor 100 can achieve the same torque (T) and power ( P), thereby increasing the efficiency of the electric motor 100.

[0054] In the example, reducing the thermal resistance from the winding to the ambient (Rthwa) is achieved by using a slot liner ( For example, slot liner 606) and laminate (for example, in gap 800). By disposing a thermally conductive gap filler in the gap between the Additionally or alternatively, the thermally conductive gap filler may be For example, a cooling tube 802) and a lamination (for example, in gap 804). Such a thermally conductive gap may be disposed in the gap between the semiconductor substrate 300 and the semiconductor substrate 300. The filler provides thermal resistance (heat flow from the windings to the lamination stack 300 and then to the environment). This reduces the resistance to the current (Rthwa) and therefore reduces Rthwa.

[0055] In the example, the thermally conductive gap filler is applied to each gap (e.g., gap 800 and / or may be disposed in or line a portion of the gap 804). Uses thermally conductive gap filler to secure slot liners and lamination stack 30 0 and the interface between the cooling tube and the lamination stack 300. can be filled.

[0056] FIG. 9 illustrates a thermally conductive layer applied to portions of gap 800 and gap 804 according to an exemplary implementation. The conductive gap filler is disposed as shown in FIG. 9 (shown in dashed lines). The thermally conductive gap filler 900 is disposed at the connection (e.g., vertical) of the slot liner 606. 3) and the inner surface of the segment 600 of the lamination stack 300. Each thermally conductive gap filler 902 (represented by a curved dashed line) can be The outer surface of each of the cooling tubes 802 and the segment in which the cooling tubes 802 are disposed 8. Alternatively, the inner surface of the semicircular channel of the .

[0057] In the example, the thermally conductive gap fillers 900, 902 are Before inserting the tube 802, the segment 600 of the lamination stack 300 is Alternatively, the thermally conductive gap fillers 900, 902 may be laminated. Before being inserted into the respective channels of the application stack 300, the slot liners 606 and and the outer surface of the cooling tube 802.

[0058] FIG. 10 illustrates an example implementation of a slot liner 606 and a segment 600. and a thermally conductive gap filler across the interface between the cooling tube 802 and the segment 600. As shown in FIG. 10, a thermally conductive gap (shown by a dashed line) is The filler 1000 is applied to the side and connection parts of the slot liner 606 and the slot liner 60 6 is disposed in a channel. The side and connection parts of the slot liner 606 and the slot liner 607 are disposed on the body or The insulator 606 is disposed along the inner surface of the segment 600 that bounds the channel in which it is disposed. The thermally conductive gap filler 1002 (shown as a curved dashed line) is and the inner surface of the semicircular channel of the segment 600 in which the cooling tube 802 is disposed. It may also be disposed across the gap 804 between the

[0059] 9-10 show one side or half of segment 600 and a portion of segment 600. 1 shows a partial cross section of a thermally conductive gap filler. A resistant gap filler may be used on the opposite side of the segment 600, and lamination It may be used with all or some of the other segments of stack 300. It should be understood that, as described above, the thermally conductive gap filler may be Before inserting the cooling tubes 802 and the insulator 606, the lamination stack 300 is The thermally conductive gap filler may be disposed in the segments, respectively. Prior to insertion into the channel of the cooling tube (e.g., cooling tube 802) and the slot The slot liner 500 may be applied to the side portions 502 and 503 of the slot liner 500. 04 and connector 506).

[0060] Various types of thermally conductive fillers can be used. For example, thermally conductive fillers contain It takes the form of a paste containing mineral oil in which conductive solid particles (e.g., metal materials) are suspended. In another example, the thermally conductive filler can be combined with a heat transfer medium (e.g., ceramic). The thermally conductive pad may take the form of a thermally conductive pad comprising a silicon polymer bonded thereto.

[0061] In an example, the thermally conductive gap filler is filled with a thermally conductive material such as aluminum oxide. Such silicone greases may include silicone greases or waxes. At normal room temperature, it can take the form of a semi-liquid or solid material, which can become liquefied or soft at elevated temperatures. The lamination stack 300 is then heated to a temperature of 100° C. and flows between the slot liner and the segments of the lamination stack 300. or to account for any irregularities in the interface between the cooling tube and the lamination stack 300. In some instances, the silicone grease or wax is provided in the form of a thin film. To provide such a thin film, a substrate, web, or other carrier may be provided. can be provided.

[0062] In another example, the thermally conductive gap filler may include a hardened sheet of material. Such materials include one or more thermally conductive particulate fillers dispersed within a polymer binder. Can be formulated to contain fillers and is available in the form of cured sheets, tapes, pads, or films. Exemplary binder materials include silicones, urethanes, thermoplastic rubbers, and Exemplary fillers include aluminum oxide, magnesium oxide, oxide and other elastomers. Includes zinc, boron nitride, and aluminum nitride.

[0063] In another example, the thermally conductive gap filler can transfer thermal energy to the windings and laminations. Hardened, form-stable, sheet-like, heat-conducting, for transfer from TAC 300 to the environment Such materials may include a urethane binder, a hardener, and one The filler may be aluminum oxide, It may include aluminum nitride, boron nitride, magnesium oxide, or zinc oxide, and the particle size The diameter may be in the range of about 1 to 50 microns or may include nanoparticles, for example.

[0064] In an example, the thermally conductive gap filler can include a phase change material, which is To facilitate ease of assembly, the composition can be free-standing and shape-stable at room temperature. The phase change material liquefies or otherwise softens at temperatures within the operating temperature range of the electric motor 100. In this case, a viscous thixotropic phase can be formed, which is essential for the formation of the slot liner and lamination stamper. between the segments of the stack 300 or between the cooling tubes and the lamination stack 300 It can be used as a free-standing thin film or printed on a substrate surface. Phase change materials that are available as clean have a relatively low thermal resistance of about 5 pounds per square inch (psi). Grease and lubricants that flow compliantly under low clamping pressure and within the operating temperature of the electric motor 100 It can act as a wax.

[0065] In another example, the thermally conductive gap filler may be coated with inner and outer release liners and a thermal compound. The present invention also includes a tape or sheet having an intermediate layer. , coated with a thin layer of pressure sensitive adhesive (PSA) to bond the slot liner and lamination strip. between the segments of the stack 300 or between the cooling tube and the lamination stack 300 A material can be applied to the heat transfer surface between the

[0066] Other exemplary thermally conductive gap filler materials include thermal interface compounds, caulking, in-place These materials may be thermally cured at room temperature or at elevated temperatures. 1, which is formed in-place within the gap (e.g., gap 800, 804). As a one or two part liquid or otherwise flowable packed reactive system, is provided in a state filled in a plurality of tubes or containers.

[0067] In another example, the thermally conductive gap filler may be ejected as a bead or from a nozzle or other orifice. comprises a thermally conductive compound that is dispensable under applied pressure when released as a mass. Materials that can be packed into tubes, cartridges, or other containers can be slotted. It can be distributed on the surface of the liner or cooling tube, which is a lamination forming gaps (e.g., gaps 800, 804) with segments of block 300 or directly into the gap formed between adjacent surfaces. can form a bead or mass of material "in place" in the gap. The bead or mass of material formed in place at least partially fills the gap; This provides a thermal conduction path between the surfaces, lowering the thermal resistance from the winding to the ambient (Rthwa). In one embodiment, the material can function as an interface material adapted to reduce as packed or otherwise supplied in a tube, cartridge, or other container , can be fully crosslinked or otherwise cured. While the material is of a flowable consistency, is generally likely to be viscoelastic and, when filled, will not appreciably displace the metal filler particles. May not exhibit settling.

[0068] The thermally conductive compound may be a thermally conductive particle or a mixture thereof. (i) A polymer gel composition. and (ii) a blend or mixture of particulate filler components applied to the surface or in the gap. When applied to the cup, the mixture is formulated to be flowable under pressure but form stable. The gel component can be, for example, a thermoplastic gel or an organic polysiloxane. The silicone gel may be a silicone gel.

[0069] The gels that can be used for the above thermally conductive compounds are silicone-based systems, i.e. polyols. Not only polysiloxanes such as siloxanes, but also polyurethanes, polyureas, and fluoro Polypolymers, chlorosulfonates, polybutadiene, butyl, neoprene, nitro Polystyrene, polyisoprene, Buna-N, ethylene-propylene (EPR), styrene- Isoprene-styrene (SIS), Styrene-butadiene-styrene (SBS), Ethylene Copolymers such as ethylene-propylene monomer (EPDM), nitrile butadiene (NB R), styrene-ethylene-butadiene (SEB), and styrene-butadiene (SB R) or copolymers such as ethylene or propylene-EPDM, EPR, or NBR Based on other polymers, which may be thermoplastic or thermosetting, such as their blends. This also includes systems based on the above.

[0070] Polymer gels may be chemically, e.g., ionically or covalently, or physically crosslinked. A continuous polymer phase or network that may be removed, and silicone or other oils, plasticizers, unreacted monomers, etc. Fluid-expanded polymer systems, including oils such as cellulose, or other materials that swell or otherwise fill the interstices of the network. The crosslink density of such a network and the ratio of the expander may be controlled. By using the polyimide, the elastic modulus, i.e., softness, and other properties of the gel can be adjusted. Magel is also referred to as a pseudogel or gel-like substance, as it has viscoelastic properties similar to those of gel. For example, relatively long cross-linked It has a "loose" crosslinked network formed by chains, but is free of, for example, fluid extenders. Or an example of a silicone gel is NuSil TM Soft materials such as "GEL-8100" It may contain silicone gel.

[0071] The polymer gel component is made of nickel, copper, tin, aluminum, and precious metals such as nickel. and non-precious metals and precious metals such as silver-plated copper, nickel, aluminum, tin, or gold. Metal-plated precious or non-precious metals, such as nickel-plated copper or silver, Precious and non-precious metals, silver or nickel plated graphite, glass, ceramics non-gold, precious or non-precious metal plated materials such as wood, plastic, elastomer, or mica Made thermally conductive by filling with thermally conductive fillers such as metals and mixtures thereof. It is possible.

[0072] FIG. 11 illustrates a method for assembling a stator 102 of an electric motor 100 according to an exemplary implementation. 1 is a flowchart of a method 1100.

[0073] The method 1100 is illustrated by one or more of blocks 1102-1110. The blocks may be illustrated sequentially. However, these blocks may also be implemented in parallel and / or as described herein. Also, various blocks may be combined into fewer blocks. , divided into additional blocks, and / or deleted based on the desired implementation. For this and other processes and methods disclosed herein, the flow chart may include: It should be understood that the functionality and operation of one possible implementation of this example is illustrated. Alternative implementations may be implemented in accordance with the As understood by the trader, depending on the functions involved, substantially simultaneous or reverse order. Within the scope of examples of the present disclosure, functions may be performed out of order from those shown or discussed, including Included.

[0074] At block 1102, the method 1100 includes: Providing a segment (e.g., segment 600) of nation stack 300 The lamination stack segment 600 includes a slot (e.g., a channel 602 or channel 604. As used herein, the term "providing" may be, for example, a lamination stack 300 or other component (e.g., a slot Regarding the segments of the liner 606, the segments are provided or installed. may be brought into a work environment for further processing (e.g., installation of other components, wiring Allows the use of segments or any other components, such as wire wrapping This includes any action for

[0075] At block 1104, the method 1100 includes forming a substrate from an electrically insulating material (e.g., insulating paper). The method includes providing a slot liner (eg, slot liner 606) that is formed in the groove.

[0076] At block 1106, the method 1100 includes applying a thermally conductive gap filler (e.g., applying a conductive gap filler (900, 1000) to the outer surface of the slot liner. .

[0077] At block 1108, the method 1100 includes: A thermally conductive gap filler was added to be disposed between the outer surface of the core and the segments. This involves inserting slot liners into the slots of the segments of the lamination stack. nothing.

[0078] At block 1110, the method 1100 includes: The wire ( ) is wrapped around the segment so that the filler is disposed between the wire and the segment. For example, this involves winding a wire 700).

[0079] The method 1100 may further include providing a first side portion, a second side portion, or a connecting portion of the slot liner. applying a thermally conductive gap filler along one or more of the thermally conductive gaps; Applying cap filler 902, 1002 to the outer surface of the cooling tube 802 and forming a segment inserting a cooling tube 802 into a semicircular channel disposed on the outer periphery of the nozzle 600; Such as attaching end turn insulation 610, 612 to segment 600. The above-described stator 102 and other steps associated with assembling the electric motor 100 are It can include.

[0080] The above detailed description refers to the accompanying drawings, which illustrate various features and operations of the disclosed system. The exemplary implementations described herein are not intended to be limiting. Certain aspects of the disclosed systems may be arranged and combined in a wide variety of different configurations. all of which are contemplated herein.

[0081] Further, unless the context suggests otherwise, each illustrated feature in the drawings may be The drawings may be used in combination with one another. Thus, the drawings generally correspond to each implementation. One or more of the illustrated features may be included, with the understanding that not all illustrated features are required. They should be considered as component aspects of the overall implementation.

[0082] In addition, any element, block, or step in this specification or claims may The enumeration of groups is for purposes of clarity. Therefore, such enumeration does not necessarily , blocks, or steps conform to a particular arrangement or are executed in a particular order. This document should not be construed as requiring or suggesting that you

[0083] Additionally, the device or system may be used or adapted to perform the functions illustrated. In some cases, the components of the device and / or system may be configured So that components are actually configured and structured to enable such performance (hardware The device may be configured to perform functions (using hardware and / or software). In some cases, the components of a device and / or system may be operated in a particular manner. Adapted, capable, or suitable to perform a function, such as It can be done.

[0084] The terms "substantially" or "about" mean that a stated property, parameter, or value is exactly the same as It is not necessary that the measurement be achieved precisely, but may be achieved within, for example, tolerances, measurement errors, and measurement precision known to those skilled in the art. Deviations or variations, including temperature limits, and other factors, may degrade the performance of the product or components that are intended to provide a characteristic. does not exclude the possibility of it occurring in large amounts.

[0085] The configurations described herein are for illustrative purposes only. As such, those skilled in the art will appreciate that other configurations may be used. configuration and other elements (e.g., machines, interfaces, operations, sequences, and groups of operations) Grouping, etc., can be used instead, and some factors may contribute to the desired result. It will be understood that many of the elements described may therefore be omitted entirely. In any suitable combination and location, as separate or distributed components, or in other configurations. A functional entity that can be implemented in combination with other components.

[0086] While various aspects and implementations are disclosed herein, other aspects and implementations will occur to those of skill in the art. It will be apparent that the various aspects and implementations disclosed herein are presented by way of example only and not by way of limitation. is not intended to define the true scope of the invention, but rather to be construed as limiting the scope of the invention to which such claims are entitled. The full scope of the subject matter is set forth in the following claims. The terminology used is for the purpose of describing particular implementations only and is not intended to be limiting. do not have.

Claims

1. 1. A stator for an electric motor, comprising: A lamination stack; a slot formed in the lamination stack; a slot liner disposed in the slot and configured to be electrically insulating; A thermal conductive member disposed in the gap between the slot liner and the lamination stack. a conductive gap filler; and a winding disposed in the slot.

2. The slot liner has a first side portion and a second side portion, and the first side portion is and a connection portion configured to connect to the two side portions of the thermally conductive gap filler. , along one or more of the first side portion, the second side portion, or the connecting portion. The stator of claim 1 , wherein

3. a cooling tube disposed in a channel disposed on the outer periphery of the lamination stack; and, Each of the cooling tubes and the outer peripheral surface of the lamination stack is provided with a gap. and a respective thermally conductive gap filler disposed in the cap. Mounted stator.

4. The channel is semicircular in shape and extends across the outer periphery of the lamination stack.

4. The stator of claim 3, wherein the stator is cut and arranged longitudinally.

5. The lamination stack includes a plurality of segments arranged adjacent to one another in a radial array. the slot is formed in a segment of the plurality of segments; The stator further comprises: an electrical insulator disposed at a first end of the segment between the winding and the segment; a first end turn insulator configured to be conductive; an electrical insulator disposed at a second end of the segment between the winding and the segment; and a second end turn insulator configured to be resistant to thermal stress. child.

6. the thermally conductive gap filler comprises a mineral oil having thermally conductive solid particles suspended therein; The stator according to claim 1 .

7. The thermally conductive gap filler comprises: (i) a polymer gel component; and (ii) a particulate filler component. The stator of claim 1 comprising a mixture of

8. 1. An electric motor assembly comprising: A stator having an open annular space, Lamination comprising a plurality of segments disposed adjacent to one another in a radial array Stack and formed between adjacent ones of the plurality of segments of the lamination stack A plurality of slots arranged in a Each slot disposed in the plurality of slots and configured to be electrically insulating With Trina, Each of the slot liners and the plurality of segments of the lamination stack. a thermally conductive gap filler disposed in each gap between the first and second electrodes; a stator including a winding disposed in the plurality of slots; a rotor disposed in the open annular space of the stator, A steel core; a plurality of magnets arranged in respective radial arrays about said steel core; and a trochanter.

9. Each slot liner includes two individual slot liners, each individual slot liner having a first side portion, a second side portion, and a connecting member for connecting the first side portion to the second side portion. and a connecting portion configured as follows: the thermally conductive gap filler is disposed on the first side portion, the front side portion, and the second side portion. the second side portion or the connecting portion is disposed along one or more of the first side portion or the connecting portion.

9. The assembly according to claim 8.

10. A plurality of cooling tubes, each of the plurality of cooling tubes being A segment of the nation stack is provided on an outer peripheral surface of the segment. a plurality of cooling tubes disposed in the channel; in each gap between the cooling tube and the outer circumferential surface of the segment. and respective thermally conductive gap fillers attached to said gap fillers. Li.

11. The channel is semicircular in shape and extends longitudinally across the outer periphery of the segment. The assembly of claim 10 , wherein the first and second electrodes are disposed in a first and second direction.

12. Each of the plurality of segments between the winding and each of the segments. a first end turn disposed at a first end of the member and configured to be electrically insulating; An insulator; a second end of each of the segments between the winding and each of the segments; and a second end turn insulator disposed on the end turn insulator and configured to be electrically insulating. The assembly of claim 8.

13. the thermally conductive gap filler comprises a mineral oil having thermally conductive solid particles suspended therein; 9. The assembly of claim 8.

14. The thermally conductive gap filler comprises: (i) a polymer gel component; and (ii) a particulate filler component. The assembly of claim 8 comprising a mixture of

15. 1. A method comprising:

1. Providing a lamination stack segment for an electric motor stator, comprising: providing a lamination stack segment including a slot; providing a slot liner formed of an electrically insulating material; applying a thermally conductive gap filler to an outer surface of the slot liner; The thermally conductive gap filler is disposed between the outer surface of the slot liner and the segment. The slot liner having the thermally conductive gap filler applied thereto is disposed between the slot liner and the thermally conductive gap filler. inserting said lamination stack into said slot of said segment; The slot liner and the thermally conductive gap filler are in contact with the wire and the segment. and winding a wire around the segment so as to be disposed between the segment and the 。

16. The slot liner has a first side portion and a second side portion, and the first side portion is and a connection portion configured to connect to the first and second side portions of the thermally conductive gap filler. The coating of the outer surface of the slot liner includes coating the first side portion, the second side portion, and applying the thermally conductive gap filler along one or more of the connecting portions.

16. The method of claim 15, comprising:

17. applying a respective thermally conductive gap filler to an outer surface of each of the cooling tubes; 、 inserting the cooling tube into a channel disposed on an outer circumferential surface of the segment.

20. The method of claim 15 further comprising:

18. Inserting the cooling tube into the channel includes inserting the cooling tube into a semicircular channel.

20. The method of claim 17, further comprising inserting a hub.

19. The wire is electrically isolated from the first end of the segment. attaching a first end turn insulator to the first end of the end cap; The wire is electrically isolated from the second end of the segment. and attaching a second end turn insulator to the second end of the component. The method according to claim 15.

20. Applying the thermally conductive gap filler comprises (i) disposing thermally conductive solid particles in the gap filler. or (ii) a mixture of a polymer gel component and a particulate filler component. The method of claim 15, comprising:

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