Molded Coolant Jacket and Spray Ring for Leak-Safe Motor Cooling
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Solution Overview
Problem
Existing electric motor systems face challenges in sealing the interface between the spray ring and stator due to manufacturing variations, and sealing components like gaskets and o-rings can degrade over time, increasing assembly time and costs.
Innovation Solution
The electric motor incorporates a coolant jacket with an integrated spray ring molded as a single unitary piece directly to the stator, eliminating the need for additional sealing components and reducing the likelihood of undesired coolant flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate spray ring and coolant jacket components are used with sealing components, then assembly flexibility is improved, but sealing reliability deteriorates due to manufacturing variations and component degradation
Solution Approach 1:
The spray ring and coolant jacket are merged into a single integrated component molded as one piece. This eliminates the interface between separate components where sealing issues occur, while the integrated design maintains assembly flexibility through the molding process. The single-piece construction ensures consistent dimensions and eliminates gasket degradation problems.
2Ease of manufacture
If separate spray ring and coolant jacket components are used, then ease of manufacture is improved, but device complexity increases due to additional sealing components
Solution Approach 1:
The spray ring and coolant jacket are combined into one molded component, reducing the total part count and eliminating the need for separate sealing components like gaskets and o-rings. This simplifies the assembly process while the molding process itself remains a standard manufacturing technique capable of producing complex geometries.
3Ease of manufacture
If separate spray ring and coolant jacket components are used with gaskets, then ease of manufacture is improved, but assembly time increases due to additional sealing components
Solution Approach 1:
By integrating the spray ring and coolant jacket into a single molded component, the assembly process is streamlined. There are no separate gaskets or sealing components to install, reducing assembly steps and time. The molding process produces the complete integrated component in one manufacturing operation.
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 sealing ability of the coolant jacket against the stator, reduces assembly time and costs, and minimizes the risk of coolant leakage, thereby improving the overall efficiency and reliability of the electric motor.
Implementation Method 1
heat produced by a motor is transferred from the motor to the coolant in order to reduce the motor operating temperature
Implementation Method 2
coolant jacket molded as a single, unitary piece in sealing engagement against an outer perimeter of the stator
Data Source
AI summary
Various methods are provided for an electric motor including a coolant jacket molded to a stator. In one embodiment, the method comprises flowing a coolant to an annular coolant passage formed between a stator and a coolant jacket molded directly to the stator, and spraying the coolant toward the stator from a nozzle formed in a spray ring molded integrally with the coolant jacket.