Electric Compressor Housing with Integrated Encapsulation Cooling
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Solution Overview
Problem
Existing electric compressors for motor vehicles face challenges in achieving compact and high-power operation while efficiently managing heat generation due to high induced electrical voltages and currents during high-speed engine operations, leading to potential operational delays and inefficiencies.
Innovation Solution
An electric compressor design featuring a control unit, electric motor, and a housing with an integrated cooling structure produced through encapsulation methods like injection molding or diecasting, which forms a cooling structure within the housing to efficiently cool the electric motor and control unit, allowing for compact and high-power operation without additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the electric compressor is designed for high-speed operation to achieve high power output, then the power output is improved, but heat generation increases leading to overheating and reduced reliability
Solution Approach 1:
The housing is produced by an encapsulation method that integrates a cooling structure directly into the housing body, merging the structural support function with the thermal management function into a single unified component, thereby enabling efficient heat dissipation while maintaining high power output
Solution Approach 2:
A cooling structure acts as an intermediary between the heat-generating electric motor and the external environment, facilitating heat transfer from the motor to the housing and then to the surrounding air, thus protecting the motor from overheating during high-speed operation
2Temperature
If additional cooling components are added to manage heat dissipation, then heat dissipation efficiency is improved, but device complexity and construction size increase
Solution Approach 1:
The cooling structure is produced integrally with the housing through an encapsulation method, combining two separate components (housing and cooling structure) into a single manufactured part, thereby improving heat dissipation without increasing device complexity or the number of components
Solution Approach 2:
The housing serves multiple functions simultaneously: it provides structural support for the electric motor and control unit, and it acts as a heat sink through the integrated cooling structure, eliminating the need for separate cooling components and reducing overall device complexity
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
The integrated cooling structure ensures reliable and efficient operation of the electric compressor by effectively dissipating heat, optimizing service life, and reducing the need for additional components, while maintaining a compact and simple construction.
Implementation Method 1
heat generation, which must be dissipated by external cooling to be able to ensure continuous operation at predetermined power levels
Implementation Method 2
the housing representing the heat sink here
Implementation Method 3
During the rotation process, the centrifugal forces which the rotation exerts on the casting compound, the casting compound is forced into all the cavities and windings of the stator
Data Source
AI summary
An electric compressor for compressing a gas, particularly configured for use in a motor vehicle, comprising a control unit, an electric motor controlled by the control unit, a compressor wheel driven by the electric motor, and a housing at least partially surrounding the electric motor. The housing is produced by an encapsulation method such that a cooling structure is formed integrally with the housing, in particular within the housing, for ensuring cooling of the electric motor and of the control unit. A method for producing the electric compressor of this kind is also disclosed.