Encapsulated Stator-Power Electronics Unit for Heat and Short-Circuit Control

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Solution Overview

Problem

Existing electric drive units for motor vehicles face issues with heat dissipation and electrical connection reliability, leading to thermal damage and safety concerns due to corrosion or vibration at connection points between the stator and power electronics.

Innovation Solution

The electric drive unit encapsulates the stator and power electronics as a single, secure unit using a material-locking connection, with cooling channels and a protective frame to enhance heat dissipation and prevent short circuits, employing injection molding for manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the stator and power electronics are connected via separate electrical connections, then the assembly and maintenance are easier, but the connection points are susceptible to short circuits due to corrosion or vibration damage

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidconnection structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the stator and power electronics into a single encapsulated unit, eliminating separate electrical connections between these components. The injection molding process creates an integrated assembly where the power electronics are directly formed onto the stator, removing vulnerable connection points while maintaining electrical connectivity through the molded structure itself.

Inventive Principle:

Principle #5Merging (Combining)

2Temperature

If cooling devices are arranged near the stator and power electronics, then heat dissipation is improved, but the components are still susceptible to thermal damage in extreme cases

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidthermal damage resistance

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The cooling channels are integrated directly into the encapsulated stator power electronics unit through the injection molding process. This merging of cooling functionality with the power electronics housing creates direct thermal pathways from heat-generating components to coolant flow, improving heat dissipation efficiency while protecting components from extreme thermal damage through the protective encapsulation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent introduces coolant as an intermediary substance that absorbs heat from the stator and power electronics through the integrated cooling channels. This mediator enables efficient heat transfer away from sensitive components, preventing thermal damage while maintaining operational temperatures within safe ranges.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If traditional electrical connections are used between stator and power electronics, then the manufacturing process is simpler, but corrosion and vibration cause short circuits leading to safety problems and unnecessary costs

Engineering Contradiction:

Improveassembly simplicityVSAvoidshort circuit prevention

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces traditional mechanical electrical connections (wires, terminals, connectors) with a monolithic molded structure created through injection molding. This substitution eliminates the mechanical connection points that are vulnerable to corrosion and vibration, while the molding process itself provides a reliable manufacturing method for creating the integrated electrical and structural connections.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 provides a safe, reliable, and cost-effective drive system with improved heat dissipation and reduced risk of short circuits, ensuring efficient operation and protection of components.

Implementation Method 1

Encapsulating or encapsulation can be understood in the context of the invention as a material-locking connection of a stator with associated power electronics to form a single unit. A corresponding encapsulation or encapsulating material, such as a resin or an injection molding material, can act as the connection means.

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Implementation Method 2

The cooling channels in the stator power electronics unit dissipate heat at the main source of the heat, and thus prevent thermal damage particularly effectively.

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 3

Some embodiments have cooling channels to cool the power electronics and the stator by dissipating heat from the electric drive unit, and particularly from the stator power electronics unit.

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20250023433A1Electric drive unit

Publication Date: 2025.01.16 DR ING H C F PORSCHE AG

AI summary

An electrical drive unit (2) for use in a motor vehicle, has a stator (4) for generating a magnetic field with a stator core and a plurality of stator windings, a rotor (6) for generating a torque based on an interaction with the magnetic field generated by the stator (4), a control unit (8) for controlling operation of the electric drive unit (2), power electronics (10) for power control and power supply of the electric drive unit (2). The stator (4) is connected electrically to the power electronics (10) and encapsulated to form a common stator power electronics unit (2′).