Sealed Stator Fluid Jacket for Motor Cooling and Insulation
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Solution Overview
Problem
Conventional cooling management systems for electric motors face inefficiencies due to inadequate insulation, leading to increased thermal resistance and operational costs, often requiring additional insulation materials that complicate manufacturing and increase costs.
Innovation Solution
A sealed stator fluid jacket with a multi-part process involving stamping, over-molding, and broaching to create precision channels for stator bars and cooling fluid passages, reducing the need for additional insulation materials by utilizing cooling fluid with dielectric properties for insulation functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional cooling management systems use inadequate insulation, then manufacturing costs and complexity are reduced, but thermal resistance increases and heat transfer efficiency deteriorates
Solution Approach 1:
The patent combines the cooling fluid passage and insulation layer into a single integrated structure. The insulation layer is formed as part of the stator assembly during the same manufacturing process, eliminating the need for separate insulation components and assembly steps while ensuring adequate thermal insulation performance.
Solution Approach 2:
The insulation layer is pre-formed as an integral part of the stator assembly before the cooling fluid passages are created. This preliminary formation of the insulation structure ensures proper thermal isolation is in place before cooling operations begin, preventing thermal interference during motor operation.
2Temperature
If additional insulation materials are added to reduce thermal resistance, then heat transfer efficiency improves, but device complexity and manufacturing costs increase
Solution Approach 1:
The cooling fluid passage and insulation layer are merged into a single integrated component structure. The insulation forms the walls of the cooling passages themselves, eliminating the need for separate insulation materials and reducing structural complexity while maintaining effective thermal management.
Solution Approach 2:
The insulation layer serves multiple functions simultaneously: it provides thermal insulation to reduce thermal resistance, forms the structural walls of the cooling fluid passages, and contributes to the overall mechanical strength of the stator assembly. This multi-functionality reduces the need for additional specialized components.
3Temperature
If cooling fluid passages are enlarged to improve cooling, then heat transfer efficiency increases, but structural strength and insulation performance worsen
Solution Approach 1:
The cooling fluid passages are strategically positioned and sized to provide optimal cooling where heat generation is highest, while the insulation layer is distributed throughout the stator structure to maintain overall thermal performance. This localized optimization allows efficient cooling without compromising overall structural integrity.
Solution Approach 2:
The stator assembly utilizes composite construction combining conductive materials for the cooling passages with insulating materials for the surrounding structure. This composite approach allows large cooling passages to be created without compromising the insulating performance and structural strength of the overall assembly.
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 approach enhances heat transfer efficiency by increasing the wetted surface area and reducing thermal resistance, allowing electric motors to operate effectively at higher power delivery for extended periods with reduced insulation requirements, potentially enabling smaller motors and lower manufacturing costs.
Implementation Method 1
a cooling fluid is able to provide heat mitigation functionality during the operation of the AC induction motor
Implementation Method 2
utilizing cooling fluid with dielectric properties for insulation functionality
Data Source
AI summary
One or more aspects of the present application relate to cooling management system implemented as part of an electric motor. Illustratively, the cooling management system corresponds to a sealed system/component that surrounding the motor stator magnetic core such that a cooling fluid is able to provide heat mitigation functionality during the operation of the AC induction motor, referred to generally as the electric motor. More specifically, illustratively, the cooling management system includes a reservoir configured to hold a cooling fluid, a pump configured to pump the cooling fluid, a heat exchanger configured to interact with the cooling fluid, and a sealed stator fluid jacket. The sealed stator fluid jacket further includes an over molded inner layer that defines an interior channel characterizing a space for the plurality of stator bars and that defines a plurality of flow channels for the flow of the cooling fluid.