Potting Stator End Turns for Electric Machine Cooling
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Solution Overview
Problem
Conventional cooling methods for electric machines that rely on direct coolant contact can increase thermal resistance, leading to higher temperatures due to the need for heat to convect to surrounding air or conduct through multiple components, which is not suitable for all coolant types.
Innovation Solution
An electric machine module with a liquid-cooled housing and potting material surrounding the stator end turns to create a thermally-conductive path, allowing for efficient heat dissipation by circulating coolant through the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If coolant is sprayed or dispersed directly onto the electric machine, then cooling efficiency is improved, but the coolant cannot be used in applications where direct contact with the electric machine is not suitable
Solution Approach 1:
The patent introduces a housing with coolant channels as an intermediary between the coolant and the electric machine. The housing receives the coolant and directs it through channels positioned adjacent to heat-generating components, allowing heat transfer without direct coolant contact with the electric machine. This resolves the contradiction by enabling efficient cooling while maintaining coolant isolation for applications where direct contact is unsuitable.
2Adaptability or versatility
If heat convects to surrounding air and conducts through multiple components to reach the coolant jacket, then coolant direct contact is avoided, but thermal resistance increases significantly causing temperature rise
Solution Approach 1:
The patent extracts the coolant delivery function from direct contact with the electric machine and embeds it within the housing structure. The housing contains integrated coolant channels that are positioned in thermal contact with heat-generating components, creating a dedicated heat transfer path that bypasses the need for heat to convect through air or conduct through multiple intervening components. This reduces thermal resistance while maintaining coolant isolation.
3Device complexity
If conventional cooling methods are used with multiple components between heat source and coolant, then device complexity is reduced, but cooling effectiveness decreases due to increased thermal resistance
Solution Approach 1:
The patent merges the housing structure with the coolant delivery system by integrating coolant channels directly into the housing. This consolidation eliminates the need for separate coolant jackets, thermal interfaces, and multiple assembly components. The merged structure provides direct thermal contact between the housing and heat-generating components while simplifying the overall device architecture, thus improving cooling effectiveness without increasing complexity.
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 reduces thermal resistance and enhances cooling efficiency by providing a direct conductive path for heat transfer from the stator end turns to the liquid-cooled housing, effectively managing heat without the need for direct coolant contact.
Implementation Method 1
The potting material extends from the stator end turns toward an inner wall of the liquid-cooled housing adjacent to the stator end turns to provide a thermally-conductive path from the stator end turns to the liquid-cooled housing
Implementation Method 2
circulating a coolant through the liquid-cooled housing to at least remove heat energy conducted from the stator end turns to the housing
Data Source
AI summary
Embodiments of the invention provide an electric machine module and a method for cooling an electric machine module. The electric machine module includes an electric machine including a stator with stator end turns, a liquid-cooled housing at least partially enclosing the electric machine, and a potting material in contact with and at least partially surrounding the stator end turns. The method includes potting at least some of the stator end turns with the potting material to provide a thermally-conductive path from the stator end turns to the housing and circulating a coolant through the housing to at least remove heat energy conducted from the stator end turns to the housing.