Hardenable Stator Seal for Electric Drive Machines

Solution Overview

Problem

Existing electric drive machines face challenges in achieving a stable and thin sealing mechanism between the stator and rotor, which affects heat transfer efficiency and mechanical stability, leading to potential cooling liquid leakage and drag losses.

Innovation Solution

A method involving a hardenable sealing means, typically made of fiber-reinforced plastic, is introduced into the stator cavity, hardened to form a rigid and integral connection with the stator, ensuring a thin and mechanically stable seal, with parameters like temperature and fiber angle controlling mechanical tension and sealing effectiveness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a thin-walled can is pressed in by means of an interference fit to seal off between stator and rotor, then sealing effectiveness is improved, but mechanical stability and connection strength deteriorate

Engineering Contradiction:

Improvesealing effectivenessVSAvoidmechanical stability

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The sealing means undergoes a parameter change from flexible (in initial state) to rigid (after hardening) through thermal or chemical hardening processes. This allows the sealing means to be inserted in a flexible state for easy installation, then transformed into a rigid structure that provides both sealing effectiveness and mechanical stability once hardened in place.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The sealing means is made from composite materials, specifically fiber-reinforced plastics, which combine the flexibility needed for installation with the strength and rigidity required for long-term sealing and mechanical stability. The fiber reinforcement provides tensile strength while the plastic matrix allows for hardening transformation.

Inventive Principle:

Principle #40Composite materials

2Loss of energy

If a thin sealing means is used to reduce air gap and improve efficiency, then heat transfer efficiency is improved, but mechanical stability and sealing reliability worsen

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidsealing reliability

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The sealing means undergoes a parameter change from flexible (in initial state) to rigid (after hardening) through thermal or chemical hardening processes. This allows the sealing means to be inserted in a flexible state for easy installation, then transformed into a rigid structure that provides both sealing effectiveness and mechanical stability once hardened in place.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The sealing means is made from composite materials, specifically fiber-reinforced plastics, which combine the flexibility needed for installation with the strength and rigidity required for long-term sealing and mechanical stability. The fiber reinforcement provides tensile strength while the plastic matrix allows for hardening transformation.

Inventive Principle:

Principle #40Composite materials

3Loss of energy

If a thin sealing means is used to reduce air gap and improve efficiency, then heat transfer efficiency is improved, but connection stability worsens

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidconnection stability

Core Design Contradiction:

Loss of energyVSStability of the object's composition

Solution Approach 1:

The sealing means undergoes a parameter change from flexible (in initial state) to rigid (after hardening) through thermal or chemical hardening processes. This allows the sealing means to be inserted in a flexible state for easy installation, then transformed into a rigid structure that provides both sealing effectiveness and mechanical stability once hardened in place.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The sealing means is made from composite materials, specifically fiber-reinforced plastics, which combine the flexibility needed for installation with the strength and rigidity required for long-term sealing and mechanical stability. The fiber reinforcement provides tensile strength while the plastic matrix allows for hardening transformation.

Inventive Principle:

Principle #40Composite materials

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 approach results in a highly efficient and stable sealing mechanism that minimizes cooling liquid leakage, enhances heat transfer, and maintains a small air gap between the stator and rotor, improving the overall efficiency of the electric drive machine.

Implementation Method 1

The hardening can be carried out, for example, by the action of heat

Methodology Applied

Scientific EffectHeat: Heating

Data Source

PatentUS10784738B2Method for producing an electric drive machine and electric drive machine

Publication Date: 2020.09.22 DR ING H C F PORSCHE AG

AI summary

A method for producing an electric drive machine, including the steps of providing a stator having a cavity for the introduction of a rotor and introducing a hardenable seal into the cavity in contact with the stator and then hardening the seal.