E-Boosting Motor Case Coolant Jacket Design
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Solution Overview
Problem
Conventional cooling systems for e-boosting devices face inefficiencies due to space constraints and manufacturing challenges, leading to suboptimal cooling performance and increased costs.
Innovation Solution
A compact motor case with a coolant jacket is designed using a combination of metallic and polymeric materials, featuring a shell member and dam member that are formed through metalworking and overmolding processes, allowing for efficient heat transfer and coolant flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling systems are used in e-boosting devices, then the cooling system can be implemented, but the cooling performance is suboptimal due to space constraints and routing limitations
Solution Approach 1:
The patent merges the cooling system integration into the motor case structure itself. The coolant jacket is formed as an integral part of the motor case, combining the motor housing and cooling system into a single unified component. This eliminates the need for separate cooling system routing and maximizes cooling efficiency within the available space.
Solution Approach 2:
The cooling channels are nested within the motor case structure. The coolant jacket is formed inside the motor case, with cooling passages integrated into the wall structure. This nesting approach allows the cooling system to occupy minimal additional space while providing effective cooling throughout the motor assembly.
2Ease of manufacture
If conventional manufacturing methods are used for the motor case and cooling system, then the components can be manufactured, but the manufacturing process is expensive and time-consuming
Solution Approach 1:
The motor case and cooling system are merged into a single integrated component manufactured in one process. The injection molding process creates both the structural motor case and the cooling jacket simultaneously, eliminating the need for separate manufacturing and assembly steps for these components.
Solution Approach 2:
The motor case serves multiple functions: it provides structural housing for the motor, acts as a coolant jacket for thermal management, and includes integrated mounting features for the compressor. This multi-functionality reduces the total number of parts and simplifies the manufacturing process.
3Device complexity
If separate components are used for the motor case and cooling system, then the components can be manufactured independently, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The motor case and cooling system are merged into a single integrated component manufactured in one process. The injection molding process creates both the structural motor case and the cooling jacket simultaneously, eliminating the need for separate manufacturing and assembly steps for these components.
Solution Approach 2:
The motor case serves multiple functions: it provides structural housing for the motor, acts as a coolant jacket for thermal management, and includes integrated mounting features for the compressor. This multi-functionality reduces the total number of parts and simplifies the manufacturing process.
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 enhances cooling efficiency, reduces material costs, and simplifies manufacturing, resulting in a compact, cost-effective, and high-performance e-boosting device cooling system.
Implementation Method 1
The motor case is configured to be received within an outer housing to cooperatively define a coolant jacket... The dam member and the outer surface are configured to define a fluid boundary for a coolant of the coolant jacket
Data Source
AI summary
A method of manufacturing a motor case for an electric motor of an e-boosting device in which the motor case is received within an outer housing to cooperatively define a coolant jacket. The method includes forming a shell member. The method also includes overmolding a dam member to the shell member. The dam member projects from an outer surface of the shell member. The overmolding of the dam member includes forming a molded through-hole through the dam member. The dam member and the outer surface are configured to define a fluid boundary for a coolant of the coolant jacket when the motor case is received in the outer housing. The through-hole defines a passage for the coolant in the coolant jacket.