E-Boosting Motor Case Coolant Jacket With Integrated Flow Dam
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Solution Overview
Problem
Conventional cooling systems for e-boosting devices face inefficiencies due to space constraints and difficulty in providing effective cooling, particularly in compact designs, which can impact operating efficiency and cost-effectiveness.
Innovation Solution
A motor case for an electric motor in an e-boosting device is designed with a metallic shell member and a polymeric dam member, forming a coolant jacket that enhances heat transfer and coolant flow, while being compact and cost-effective, using metalforming and overmolding processes for efficient manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional cooling system is used in an e-boosting device, then the structure is simple, but the cooling efficiency is insufficient and space constraints are not adequately addressed
Solution Approach 1:
The motor case integrates multiple functions: it houses the electric motor, forms part of the coolant jacket, and includes integrated dams for flow control. The shell member and dam member are molded as a single piece, combining structural support and cooling functions in one component, thereby improving cooling efficiency without proportionally increasing complexity
Solution Approach 2:
The motor case serves multiple purposes simultaneously: it provides mechanical housing for the motor, acts as a thermal management component through the coolant jacket, and controls coolant flow through integrated dams. This multi-functionality addresses space constraints while maintaining effective cooling
2Volume of moving object
If the cooling circuit is made compact to address space constraints, then the device size is reduced, but the routing and cooling performance are negatively affected
Solution Approach 1:
The coolant jacket utilizes the radial dimension by forming an annular space between the motor case outer surface and the inner housing surface. This three-dimensional coolant pathway allows effective cooling in a compact radial space without compromising cooling performance
Solution Approach 2:
The motor case is nested within the housing, with the coolant jacket formed in the annular space between them. The dam member is molded onto the shell member, creating a nested structure that maximizes space utilization while maintaining cooling effectiveness
3Adaptability or versatility
If different materials are used for the shell member and dam member, then the functional requirements are better met, but the manufacturing complexity increases
Solution Approach 1:
The motor case is formed as a composite structure with a metallic shell member providing structural strength and thermal conductivity, and a polymeric dam member providing chemical resistance and flow control. These different materials are molded together in a single integrated component
Solution Approach 2:
The metallic shell member and polymeric dam member are molded together in a single integrated component using a two-material injection molding process. This combines the advantages of different materials (metallic strength and thermal conductivity, polymeric chemical resistance) while maintaining manufacturing efficiency through a single-step process
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
The solution provides improved cooling efficiency, compactness, and cost-effectiveness by optimizing the motor case design to enhance heat transfer and coolant flow, addressing the limitations of conventional cooling systems.
Implementation Method 1
The shell member and the dam member are configured to be received within an outer housing to define the coolant jacket
Implementation Method 2
a cooling system may be provided that directs flow of a coolant through the device to maintain operating temperatures within a predetermined range
Data Source
AI summary
A motor case for an electric motor of an e-boosting device is configured to be received within an outer housing to cooperatively define a coolant jacket. The motor case includes a shell member that at least partly defines a motor cavity for receiving the electric motor. The motor case also includes a dam member that is fixed to the shell member. The dam member projects from the shell member in an outboard direction from an outer surface of the shell member. The shell member and the dam member are configured to be received within the outer housing to define the coolant jacket and with the dam member partitioning the coolant jacket. The dam member is made of a different material from the shell member.