Electroplated Stator Laminations for Corrosion-Resistant Pump Motors
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Solution Overview
Problem
Existing liquid pumps for cooling circuits in motor vehicles face challenges in durability due to corrosion and require significant installation space due to large magnetic air gaps caused by coating processes.
Innovation Solution
The stator laminations of the electric motor are electroplated with a metallic coating resistant to the transported medium, ensuring corrosion protection and maintaining a thin magnetic air gap, while the uncoated areas are coated with plastic, and a primer is used for enhanced adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the stator and rotor are overmolded with plastic to protect against corrosion, then durability is improved, but the magnetic air gap increases and installation space increases
Solution Approach 1:
Instead of uniformly coating the entire stator and rotor with plastic, the patent applies electroplating only to specific areas that require corrosion protection (such as the stator laminations and contact pins), while leaving other areas uncoated or coated with different materials. This localized approach provides necessary protection without adding excessive thickness that would increase the magnetic air gap and installation space requirements.
Solution Approach 2:
The patent changes the coating method from thick plastic overmolding to thin electroplating layers. By changing the coating parameters (thickness, material composition, application method), the solution achieves corrosion protection with minimal added thickness, thereby maintaining a small magnetic air gap and reducing installation space while improving durability.
2Reliability
If a thick coating is applied to protect against corrosion, then durability is improved, but the magnetic air gap increases
Solution Approach 1:
The patent changes the coating parameters by using electroplating to apply very thin metallic layers (typically micrometers thick) compared to thick plastic coatings. This parameter change in coating thickness and material density provides effective corrosion protection while adding minimal dimension, thus maintaining a small magnetic air gap and preserving electrical efficiency.
Solution Approach 2:
The patent employs composite coating strategies, combining electroplated metallic layers (for corrosion protection) with selective plastic coating areas. This composite approach allows the metallic plating to provide the necessary protective function with minimal thickness, while plastic coating is applied only where mechanical protection is needed, optimizing both durability and magnetic air gap maintenance.
3Reliability
If the entire stator is coated with plastic to protect against corrosion, then durability is improved, but electrical efficiency decreases due to increased magnetic air gap
Solution Approach 1:
The patent applies different coating strategies to different parts of the stator. Critical areas such as the stator laminations and contact pins receive electroplating for corrosion protection, while areas close to the magnetic air gap are left uncoated or receive minimal coating. This localized differentiation ensures durability where needed while preserving electrical efficiency by maintaining a small magnetic air gap in critical electromagnetic zones.
Solution Approach 2:
The patent changes the coating parameters by using thin electroplating layers instead of thick plastic coatings, particularly in areas affecting the magnetic air gap. By controlling the coating thickness and material properties, the solution achieves corrosion protection without significantly increasing the magnetic air gap, thereby maintaining electrical efficiency while improving durability.
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 solution enhances the motor's durability and reduces installation space without compromising electrical efficiency by effectively protecting against corrosion and minimizing the magnetic air gap.
Implementation Method 1
The stator laminations of the stator are electroplated at least in part
Implementation Method 2
the stator laminations and contact pins are pretreated with a primer. In this way, particularly good adhesion of all coats is ensured
Data Source
AI summary
A pump for liquids is provided, comprising a pump chamber in which a bucket wheel is mounted on a bearing so that it can rotate, and an electric motor with a stator and a rotor. The stator has stator laminations and coils, and is coated with plastic in some parts and an electric/electronic activation device. The pump is intended to have a long service life and at the same time require as little installation space as possible. This is achieved by the stator laminations of the stator being at least in part electroplated.