Copper-Graphene Stator Bars for Higher Power Density
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Solution Overview
Problem
Current stator units for electric motors in vehicles face challenges in increasing electric power density and reducing energy consumption to meet the demands of environmentally friendly zero-emission vehicles.
Innovation Solution
The use of conductive composite stator units with copper-graphene multilayer composites for the conductive bars, which include a stator core, conductive bars coated with multiple copper-graphene layers, and an insulator layer to enhance conductivity and reduce energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional conductive bars are used in stator units, then manufacturing simplicity is maintained, but electric power density and conductivity are insufficient
Solution Approach 1:
The patent applies composite materials by coating conductive bars with copper-graphene multilayer composites. The conductive bars consist of a central portion (copper or aluminum) surrounded by an outer layer comprising multiple alternating copper and graphene layers. This composite structure combines the high electrical conductivity of copper with the exceptional electron transport properties of graphene, achieving superior electric power density while maintaining structural integrity.
Solution Approach 2:
The patent implements parameter changes by modifying the conductivity and structural parameters of conductive bars through the copper-graphene multilayer composite coating. The outer layer has specific thickness parameters (each Cu-Gr layer: 0.1-0.5 micron, total outer layer: 0.2-200 micron) and graphene volume fraction (0.002%-0.2%), which optimize electrical conductivity and power density while controlling the complexity of the structure.
2Reliability
If thicker copper coatings are applied to conductive bars, then conductivity is improved, but energy losses increase due to skin effect
Solution Approach 1:
The patent applies segmentation by dividing the outer layer into multiple thin alternating copper and graphene layers instead of using a single thick copper coating. Each Cu-Gr layer has a thickness of 0.1-0.5 micron, creating a segmented multilayer structure that reduces skin effect losses while maintaining high conductivity through the synergistic combination of copper and graphene's electron transport properties.
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 copper-graphene multilayer composites improve electric power density and lower energy consumption by leveraging the skin effect of electron transport, providing high conductivity and mechanical stability while reducing energy losses.
Implementation Method 1
Each conductive bar comprises a central portion and an outer layer disposed thereabout for electrical current to flow therethrough
Implementation Method 2
The copper-graphene multilayer composites improve electric power density and lower energy consumption by leveraging the skin effect of electron transport
Data Source
AI summary
A conductive composite stator unit for an electric motor of a vehicle is provided. The stator unit comprises a stator core comprising a body having a first core end and an opposing second core end. The stator unit further comprises a plurality of conductive bars extending from the first core end to the second core end. Each conductive bar comprises a straight portion disposed in one of the slots such that the respective conductive bar is in contact with the stator core. Each conductive bar comprising a central portion and an outer layer disposed thereabout for electrical current to flow therethrough relative to the longitudinal axis, the outer layer comprises at least two copper-graphene (Cu-Gr) layers. Each Cu-Gr layer comprises a copper layer and a graphene layer. The stator unit further comprises an insulator layer disposed about each of the plurality of conductive bars.