Overmolded Stator Structure for Lightweight Motor Cooling
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Solution Overview
Problem
Existing electric motor stators face challenges in achieving a balance between mechanical strength, weight reduction, and reliable production, particularly for use in motor vehicles.
Innovation Solution
A stator design featuring a metal framework overmolded with thermoplastic, creating a lightweight yet strong carrier component. The metal framework is strategically used to provide rigidity and strength, while the thermoplastic casing surrounds and shields the metal components, allowing for efficient heat dissipation and environmental protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a stator is made entirely of metal to increase mechanical strength and rigidity, then the mechanical strength and rigidity are improved, but the weight increases significantly
Solution Approach 1:
The stator is constructed as a composite structure combining a metal framework (aluminum or aluminum alloy) with a plastic casing (polyamide or polypropylene). The metal framework provides the necessary mechanical strength and rigidity, while the plastic casing reduces overall weight and provides environmental protection. This composite approach resolves the contradiction by integrating materials with complementary properties.
Solution Approach 2:
Instead of using metal throughout the entire stator, the metal framework is strategically positioned only where mechanical strength and rigidity are required. The plastic material is used in regions where weight reduction and environmental protection are priorities. This localized material distribution optimizes the strength-to-weight ratio.
2Weight of moving object
If a stator is made entirely of plastic to reduce weight, then the weight is reduced, but the mechanical strength and rigidity are insufficient
Solution Approach 1:
The combination of metal framework and plastic casing creates a composite structure that achieves both weight reduction and sufficient mechanical strength. The plastic casing provides adequate strength for non-structural functions while the metal framework reinforces critical load-bearing areas.
Solution Approach 2:
Metal reinforcement is applied locally at the framework level rather than throughout the entire stator body. This localized metal presence provides the necessary structural support while maintaining overall low weight, as the majority of the stator volume consists of lightweight plastic material.
3Object-affected harmful factors
If the metal framework is completely overmolded with plastic to provide environmental protection, then the environmental protection is improved, but the manufacturing complexity increases
Solution Approach 1:
The stator is divided into two distinct components: a metal framework and a plastic casing. These components are manufactured separately using optimized processes for each material, then assembled through overmolding. This segmentation allows each component to be manufactured with appropriate techniques without the complexity of creating a fully integrated multi-material part in one step.
Solution Approach 2:
The plastic casing is designed to envelop and protect the metal framework, with the metal structure nested within the plastic housing. This nested configuration provides comprehensive environmental protection while maintaining a relatively simple manufacturing process, as the plastic casing acts as a protective shell rather than requiring complex integration of multiple components.
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 design achieves increased rigidity and reduced weight compared to all-plastic or all-metal stators, while ensuring high mechanical strength and simplified production processes, making it suitable for motor vehicle applications.
Implementation Method 1
a carrier portion (29) having an externally located surface (34), the externally located surface (34) facing in a radial direction (r) orthogonal to the longitudinal axis (L); the carrier portion (29) comprising a metal framework (10) overmolded by a thermoplastic carrier plastic (28)
Implementation Method 2
The connecting configuration (54, 36) is welded to the counterpart connecting configuration (36)
Implementation Method 3
the metal framework (10) is surrounded at least in portions by a plastic casing (28) made of carrier plastic (28)
Implementation Method 4
Embodied in the stator are coolant channels through which a cooling medium can flow in order to discharge heat from the stator
Data Source
AI summary
A stator for an electric motor, encompassing a carrier component that extends along a virtual longitudinal axis defining an axial direction, the carrier component that is notionally passed through centrally by the virtual longitudinal axis including a carrier portion having an externally located surface; the externally located surface facing in a radial direction orthogonal to the longitudinal axis; the carrier portion including a metal framework overmolded by a thermoplastic carrier plastic, so that the metal framework is surrounded at least in portions by a plastic casing made of carrier plastic; the stator including a cover at at least one axial longitudinal end of the carrier portion; the cover encompassing a connecting configuration having cover plastic compatible with or identical to the carrier plastic; the plastic casing including a counterpart connecting configuration; the connecting configuration being welded to the counterpart connecting configuration.