Axial Flux Electric Water Pump With Reduced Air Gap Packaging
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Solution Overview
Problem
The existing electric water pumps in heat pump systems for eco-friendly vehicles suffer from increased axial and radial sizes due to the presence of a waterproof cover, which deteriorates pump performance and complicates packaging in limited vehicle spaces.
Innovation Solution
The electric water pump design incorporates an axial flux motor and minimizes the size of the air gap between the stator and rotor assemblies, along with a waterproof cover that partitions the housing into wet and dry areas, to reduce the axial size and enhance motor output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a waterproof cover is provided between the stator and rotor of the driving motor to prevent cooling water from being introduced into the coils, then the reliability of the motor is improved, but the air gap between the stator and rotor increases, causing the performance of the electric water pump to deteriorate
Solution Approach 1:
The patent removes the traditional waterproof cover component entirely and replaces it with a waterproof coating layer applied directly to the stator and rotor surfaces. This extraction of the intermediate waterproof cover eliminates the air gap issue while maintaining coil protection through the coating's inherent waterproof properties.
Solution Approach 2:
The patent replaces the mechanical waterproof cover structure with a chemical/physical waterproof coating system. The coating forms a protective barrier against cooling water without requiring a physical cover that would increase air gap, thus substituting a mechanical solution with a material-based solution.
2Reliability
If a waterproof cover is provided inside the electric water pump to protect the motor coils, then the reliability is improved, but the axial size and radial size of the electric water pump increase, making it difficult to secure package space in limited vehicle space
Solution Approach 1:
The patent extracts and eliminates the waterproof cover component that occupies axial and radial space. By applying waterproof coating directly to the motor components, the design removes the intermediate structural element that increases overall pump dimensions.
Solution Approach 2:
The patent uses thin waterproof coating films applied to the stator and rotor surfaces instead of a bulky waterproof cover. These thin films provide the necessary protection while occupying minimal space, thus reducing the overall axial and radial dimensions of the electric water pump.
3Productivity
If the air gap between the stator and rotor is reduced to improve motor output, then the productivity is improved, but it becomes more difficult to prevent cooling water from being introduced into the coils
Solution Approach 1:
The patent replaces the mechanical waterproof cover with a waterproof coating system that can function effectively in reduced air gap configurations. The coating provides continuous protection without requiring the physical space of a cover, enabling smaller air gaps while maintaining reliability.
Solution Approach 2:
The patent employs composite material structures where waterproof coating materials are applied to the stator and rotor surfaces. These composite surfaces provide both magnetic/electrical functionality and waterproof protection, allowing reduced air gap design while preventing cooling water intrusion.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design effectively reduces the axial size of the electric water pump, improves motor output by minimizing air gaps, and facilitates easier packaging in limited vehicle spaces without compromising performance.
Implementation Method 1
The electric water pump pumps cooling water while an impeller is rotated by power generated by a driving motor operated by electric energy
Implementation Method 2
The rotary shaft may be rotatably supported through the upper bearing and the lower bearing
Data Source
AI summary
An electric water pump includes: a housing with a cooling water inlet and a cooling water outlet; a stator assembly provided inside the housing and having stator coils on upper and lower surfaces thereof, respectively; a rotor assembly including a rotary shaft rotatably supported on the housing, a first magnetic body provided at an upper portion of the stator assembly, and a second magnetic body provided at a lower portion of the stator assembly; and an impeller provided to rotate integrally with the rotary shaft of the rotor assembly.