Integrated Bus Bar Stator with Internal Cooling Jacket
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Solution Overview
Problem
Conventional electric motor designs with integrated bus bars are inefficient in terms of space, material usage, and manufacturing complexity, particularly for axial flux motors, leading to increased costs and reduced performance due to the need for precise wire winding and separate bus bar holders.
Innovation Solution
Embedding bus bars within the motor housing and connecting individual stator coils directly to them, allowing for flexible geometry and reduced component costs through methods like welding, crimping, or overmoulding, while incorporating an internal cooling jacket for efficient heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single continuous wire is used to create stator phases, then manufacturing simplicity is improved, but flexibility in winding geometry is reduced and precision requirements increase
Solution Approach 1:
The patent divides the continuous wire winding approach into segmented bus bar components. Instead of using a single continuous wire for stator phases, the invention uses separate bus bar segments that are individually positioned and connected to stator coils. This segmentation provides flexibility in winding geometry for axial flux motors while maintaining manufacturing simplicity through modular assembly.
Solution Approach 2:
The patent transitions from planar wire winding to three-dimensional bus bar structures that protrude radially from the housing. This dimensional change allows bus bars to accommodate complex winding geometries in axial flux motors by extending in multiple spatial directions, providing the needed geometric flexibility without increasing manufacturing complexity.
2Ease of operation
If separate bus bar holders are used to attach bus bars, then ease of assembly is improved, but weight and volume increase
Solution Approach 1:
The patent merges the bus bar holder function directly into the motor housing structure. Instead of using separate bus bar holder components, the housing itself is designed with integrated features to attach and position the bus bars. This merging eliminates the need for additional parts, reducing both weight and volume while maintaining ease of assembly through the integrated design.
3Ease of operation
If bus bars are placed on the housing exterior, then ease of connection is improved, but motor size increases
Solution Approach 1:
The patent nests the bus bars within the motor housing structure rather than placing them on the exterior. The bus bars are positioned inside the housing, utilizing the internal space efficiently. This nesting approach maintains ease of connection by providing accessible connection points while keeping the overall motor footprint compact and meeting standard size specifications.
4Quantity of substance
If thicker magnet wire is used in axial flux motors, then current carrying capacity is improved, but manufacturing complexity increases
Solution Approach 1:
The patent extracts the winding function from the motor manufacturing process by using pre-fabricated bus bar components. Instead of winding thicker magnet wire during motor assembly (which increases manufacturing complexity), the bus bars are manufactured separately with the required current carrying capacity and then installed as complete components. This extraction of the winding operation simplifies the overall manufacturing process while maintaining high current capacity.
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 enhances manufacturability, power, torque, efficiency, and material usage, improving performance in electric vehicles and renewable energy applications by reducing weight, size, and production complexity.
Implementation Method 1
an internal cooling jacket for efficient heat management
Implementation Method 2
allow coolant to come into direct contact with a plurality of stator coils and exposed bus bars
Data Source
AI summary
An axial or radial flux electric motor or generator consisting of a housing, a stator assembly(s), and rotor(s) where the stator assembly and rotor are aligned with each other while allowing an air gap between the stator and rotor, with electromagnetic forces being applied between the two when the rotor rotates within the stator. Stator coils are connected by one or more conductive bus bars integrated into the motor housing where the stator coils are affixed to the bus bars to create individual stator phases. The stator assembly is enclosed within a cooling jacket where cooling channels flow a coolant media directly over the stator coils during operation. The flow of coolant is controlled by a set of permeable dividers that direct coolant over the surface area of the coil evenly.