Core-Bobbin Assembly Structure for Lighter Motor Cooling
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Solution Overview
Problem
Conventional water-cooled motors in eco-vehicles face issues with high weight, increased heat generation, core delamination, and reduced heat transfer efficiency due to the use of heavy steel support rings and multiple components, leading to potential motor failure and decreased performance.
Innovation Solution
A core-bobbin assembly structure that omits the support ring, O-ring, and gasket, utilizing a recessed outer surface on the core and a covering outer circumference sheath on the bobbin to enhance fixation, prevent delamination, and increase the heat transfer area, thereby reducing weight and improving cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a steel plate support ring is used to form the coolant passage portion, then the structural strength and coolant passage formation are improved, but the weight of the motor increases significantly
Solution Approach 1:
The patent merges the support ring and coolant passage portion into a single integrated structure. The coolant passage portion is formed directly in the support ring through a through-hole, eliminating the need for separate coolant passage components. This integration maintains structural strength while reducing overall weight by consolidating multiple functions into one component.
Solution Approach 2:
The patent extracts the coolant passage function from separate components and integrates it directly into the support ring. By forming the coolant passage portion as a through-hole in the support ring, the design removes unnecessary additional parts while maintaining both structural support and cooling functions.
2Reliability
If multiple components (gasket, O-ring, support ring) are used to achieve water tightness and support, then the sealing performance is improved, but the number of components and assembly complexity increase
Solution Approach 1:
The patent combines multiple sealing and support functions into fewer integrated components. The support ring with integrated coolant passage portions eliminates the need for separate gaskets and O-rings in certain configurations, reducing component count while maintaining water tightness through the integrated design.
Solution Approach 2:
The support ring is designed to perform multiple functions simultaneously: structural support, coolant passage formation, and sealing. By making the support ring a multi-functional component that incorporates coolant passage portions directly, the patent reduces the need for additional specialized components.
3Temperature
If a hollow support ring structure is used for coolant passage, then the cooling function is improved, but the weight and structural complexity increase
Solution Approach 1:
The patent segments the support ring into multiple regions with coolant passage portions formed at specific locations. Instead of using a completely hollow support ring structure, coolant passage portions are strategically positioned to provide effective cooling where heat generation occurs, reducing unnecessary material while maintaining cooling efficiency.
Solution Approach 2:
The patent applies coolant passage portions at specific local regions of the support ring where cooling is most needed, rather than making the entire support ring hollow. This localized approach provides effective cooling at critical areas while minimizing the removal of material, thus reducing weight while maintaining cooling performance.
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 solution reduces the motor's weight, decreases the number of components, prevents core delamination, and significantly increases the heat transfer area, leading to improved cooling performance and reduced fuel consumption.
Implementation Method 1
Heat transfer using the injected coolant is performed while the injected coolant flows through a water passage formed in the motor
Data Source
AI summary
The present invention relates to an improved structure of a core-bobbin assembly without using a support ring, an O-ring, and a gasket which support and cool the core-bobbin assembly of a motor for a vehicle, so that a weight decreases, and a heat transfer area increases. The present invention also relates to a motor cooling method using the same. In the present invention, an outer circumference sheath (210) is added to a bobbin to cover an entirety of a core outer circumferential portion (110) including a cooling surface press-inserted into and in contact with a housing, that is, a recessed outer circumferential surface (120) formed on the core outer circumferential portion (110).