Integrated Stator Can Structure for Liquid-Cooled Electric Machines
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Solution Overview
Problem
The increasing demand for efficient and cost-effective electric motors for electric vehicles poses challenges in developing compact, high-power motors with reduced heat losses and improved recyclability, while also requiring automated and inexpensive production methods.
Innovation Solution
The electric machine features a stator component formed as a single piece, comprising a stator laminated core overmolded with a magnetically neutral and electrically insulating plastics workpiece to create a can for cooling, along with insulating sleeves and end disks for conductor tracks, enabling efficient cooling and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a can is added to separate stator and rotor for coolant cooling, then cooling efficiency is improved, but device complexity increases
Solution Approach 1:
The patent combines the can and insulating structure into a single integrated component formed from one piece of electrically insulating material. The can's separating function and the insulating structure's electrical insulation function are merged into one component, reducing part count while maintaining both cooling efficiency and electrical insulation.
Solution Approach 2:
The integrated component serves multiple functions simultaneously: it acts as the can for separating stator and rotor, provides electrical insulation between conductor tracks and stator laminated core, and facilitates coolant flow for cooling. This multi-functionality reduces device complexity while achieving effective cooling.
2Reliability
If multiple separate components (can, insulating structure) are used, then functional requirements are met, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent merges the can and insulating structure into a single integrated component formed from one piece of electrically insulating material through processes like injection molding. This consolidation reduces the number of parts to manufacture, assemble, and inspect, thereby lowering production costs while maintaining all necessary functions.
3Reliability
If conventional separate components are used, then functional requirements are met, but recyclability is reduced
Solution Approach 1:
By combining the can and insulating structure into a single component made from one material type (electrically insulating material), the patent simplifies end-of-life processing. The integrated design reduces material diversity, making recycling and disposal more straightforward compared to separate metal and plastic components that would require different processing streams.
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 results in a compact, high-efficiency electric machine with reduced component count, lower production costs, and improved recyclability, while also enabling automated production and enhanced cooling efficiency.
Implementation Method 1
A liquid coolant commonly is used for this purpose and flows around the windings
Implementation Method 2
A liquid coolant commonly is used for this purpose and flows around the windings
Implementation Method 3
The plastics workpiece is the can... a stator component formed as a single piece and composed of the stator laminated core and of a plastics workpiece molded thereon
Data Source
AI summary
An electric machine has a rotor and a stator defined by a stator laminated core (15). The rotor and the stator are separated from one another by a can (20) for the cooling of the stator using a liquid coolant. The electric machine has a stator component (100) formed as a single piece and composed of the stator laminated core (15) and of a plastics workpiece (10) molded thereon. The plastics workpiece (10) is formed as the can (20).