Disc Rotor Stator Cooling Channels for Direct Coil Heat Removal

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Solution Overview

Problem

Existing disc rotor machines face inefficiencies in thermal transmission due to the use of casting compounds, leading to limited power density and inefficient heat dissipation.

Innovation Solution

The stator incorporates a carrier wheel that forms a cooling channel portion, directly accepting coil windings and separating the holding function from the cooling fluid conducting function, allowing for efficient cooling and easier manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If guide plates are used with casting compound to cool coils, then cooling function is provided, but thermal transmission efficiency is insufficient and power density is limited

Engineering Contradiction:

Improvecooling efficiencyVSAvoidpower density

Core Design Contradiction:

TemperatureVSPower

Solution Approach 1:

The stator is divided into modular core segments that are rigidly connected by retaining rings, allowing the cooling device to be integrated as a separate functional module rather than being cast as a single piece. This segmentation enables optimized thermal pathways and better heat dissipation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A dedicated cooling device with cooling channels is introduced as an intermediary component between the coils and the external cooling system. This separate cooling structure provides efficient thermal transmission without relying on casting compound, directly addressing the heat dissipation needs of the coils.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If guide plates are used for cooling, then cooling function is achieved, but heat dissipation path is long and inefficient

Engineering Contradiction:

Improveheat dissipationVSAvoidradial path length

Core Design Contradiction:

TemperatureVSLength of stationary object

Solution Approach 1:

The cooling channels are designed to extend axially between the rotor discs rather than relying solely on radial heat dissipation. This dimensional change creates shorter and more direct thermal pathways from the coils to the cooling medium, significantly improving heat dissipation efficiency.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Strength

If retaining ring and core segments form torque support unit, then mechanical strength is provided, but cooling fluid conduction function is not optimized

Engineering Contradiction:

Improvetorque supportVSAvoidcooling device integration

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The functional separation divides the stator into a mechanical support unit (retaining ring with core segments) and a thermal management unit (carrier wheel with cooling channels). This segmentation allows each component to be optimized for its specific function and manufactured independently, simplifying the overall manufacturing process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The carrier wheel is designed to serve multiple functions: it provides structural support for the coil windings, forms sealed cooling channels for efficient fluid conduction, and facilitates heat dissipation. This multi-functionality integrates cooling optimization without compromising mechanical strength.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 enhances power density by enabling direct cooling of coils and separates the torque support and coolant sealing functions, resulting in improved thermal management and manufacturing efficiency.

Implementation Method 1

a cooling device which cools the coils during operation

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 2

the carrier wheel forming a cooling channel portion of the cooling device that (directly) accepts at least one of the coil windings

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS12334786B2Disc rotor machine with stator having core segents, with rotor disc with cooling device

Publication Date: 2025.06.17 SCHAEFFLER TECHNOLOGIES AG & CO KG

AI summary

A disc rotor machine for a motor vehicle drive is disclosed that includes a disc-shaped stator. The stator has a plurality of core segments-, which are distributed in a circumferential direction and are rigidly connected to one another by means of at least one retaining ring, and a plurality of coil windings each extending around a core segment. The disc rotor machine also comprises a rotor which is mounted rotatably relative to the stator, the rotor having a first rotor disc arranged adjacent to the stator towards a first axial side and a second rotor disc arranged adjacent to the stator towards a second axial side opposite the first axial side, which rotor discs can be driven by a plurality of coils of the stator which are distributed in a circumferential direction and include the core segments and coil windings. The disc rotor machine further comprises a cooling device which cools the coils during operation, the stator having a carrier wheel which accommodates the coil windings and is connected to the at least one retaining ring, the carrier wheel forming a cooling channel portion of the cooling device that directly accommodates at least one of the coil windings.