Multi-Material Pump Housing for Leak-Safe Stator Encapsulation
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Solution Overview
Problem
Existing pump devices for motor vehicle fluid circuits face challenges in production complexity and risk of stator core damage due to thermal expansion mismatch between the stator core and its thermoset overmold, which can lead to leakage.
Innovation Solution
A pump device with a multi-component main body comprising a thermoset inner region and a thermoplastic outer region, where the thermoset forms the base and determines the coefficient of thermal expansion, and the thermoplastic facilitates easier connection to other components, while a seal ensures fluid-tight enclosure of the stator core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the stator core is overmolded with a thermoset main body to match thermal expansion coefficients, then the reliability is improved by preventing cracks and leakage, but the ease of manufacture deteriorates due to difficulty in connecting to other components
Solution Approach 1:
The main body is divided into two distinct material regions: an inner region made of thermoset material for fluid-tight enclosure and an outer region made of thermoplastic material for easy connection. This segmentation allows each region to fulfill its specific function optimally without compromise.
Solution Approach 2:
Different regions of the main body are assigned different material properties: the inner region uses thermoset material with thermal expansion coefficient matching the stator core for reliability, while the outer region uses thermoplastic material with favorable processing and connection properties. This local differentiation resolves the contradiction between reliability and ease of manufacture.
2Reliability
If the main body consists of a single thermoset material to ensure thermal expansion matching, then the reliability is improved, but the device complexity increases due to manufacturing difficulties
Solution Approach 1:
The main body is constructed as a composite structure with an inner region of thermoset material and an outer region of thermoplastic material. This composite approach combines the thermal expansion benefits of thermoset with the manufacturing advantages of thermoplastic, reducing overall device complexity while maintaining reliability.
3Ease of manufacture
If the thermoplastic forms the entire main body to simplify connections, then the ease of manufacture is improved, but the reliability deteriorates due to thermal expansion mismatch
Solution Approach 1:
The main body is segmented into functional regions: the inner region uses thermoset material to match the stator core's thermal expansion coefficient and prevent cracks, while the outer region uses thermoplastic material to provide easy connection capabilities. This segmentation eliminates the need to choose between reliability and ease of manufacture.
Solution Approach 2:
The main body exhibits local quality differentiation where the inner region is optimized for thermal compatibility and the outer region is optimized for manufacturing and connection. This localized material assignment allows the structure to simultaneously achieve both reliability and ease of manufacture.
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
Simplifies the production of pump devices by allowing easier connection to other components and reduces the risk of thermal damage to the stator core, maintaining fluid tightness and preventing leakage.
Implementation Method 1
The main body comprises a thermoset and a thermoplastic. Because of this multi-component main body, the main body can have a coefficient of thermal expansion that is comparable to that of the stator core. At the same time, the region of the main body with the thermoplastic can be used to connect the main body to other components of the pump device.
Implementation Method 2
The pump device additionally comprises a rotor which can be set in rotation relative to the stator. This can be done, for example, by means of electromagnetic forces.
Data Source
AI summary
A pump device, in particular for a fluid circuit in a motor vehicle, comprising a stator, which has a stator core and a main body, and a rotor, wherein the rotor can be set in rotation relative to the stator, wherein the stator core is enclosed by the main body in a fluid-tight manner, and wherein the main body comprises a thermoset and a thermoplastic.