Axial Flux Motor Stator Cooling Through SMC Core Heat Conduction
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Solution Overview
Problem
Axial flux motors face inefficiencies in heat dissipation due to the limitations of external liquid cooling jackets, which compromise the compact form factor and result in diminished motor efficiency, especially when relying on air-cooling methods that incur windage losses.
Innovation Solution
A stator assembly with a heat exchanger jacket configured to circulate a heat transfer liquid, incorporating molded soft magnetic composite materials with high thermal conductivity, and a yoked or yokeless design that enhances heat transfer by direct contact with the heat exchanger, allowing for improved cooling efficiency while maintaining a compact form factor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If external liquid cooling jackets are used for axial flux motors, then heat dissipation is improved, but the compact form factor is compromised
Solution Approach 1:
The patent combines the magnetic core and heat exchanger into a single integrated component. The heat exchanger is formed as an integral part of the molded soft magnetic composite material, eliminating the need for separate external cooling jackets while maintaining effective heat dissipation from the stator windings.
Solution Approach 2:
The heat exchanger channels are nested within the magnetic core structure itself. The cooling channels are formed inside the molded soft magnetic composite material, allowing the heat exchanger to be contained within the existing motor footprint without increasing overall volume.
2Volume of moving object
If air-cooling methods are used for axial flux motors, then the compact form factor is maintained, but motor efficiency is diminished due to windage losses
Solution Approach 1:
The patent transitions from air-cooling to liquid cooling by incorporating heat exchanger channels that circulate coolant through the magnetic core. This hydraulic cooling system provides superior heat transfer efficiency compared to air cooling, reducing windage losses while maintaining the compact form factor.
3Device complexity
If conventional cooling methods are used, then the motor structure is simple, but heat transfer efficiency is insufficient
Solution Approach 1:
The patent uses molded soft magnetic composite material that integrates both magnetic and thermal management functions. The composite material incorporates heat exchanger channels directly into the magnetic core, creating a multi-functional component that improves heat transfer efficiency without significantly increasing structural 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
The solution significantly enhances heat transfer efficiency, potentially increasing cooling effectiveness by dozens of times, minimizing magnetic leakage, and maintaining the compact design of axial flux motors, thereby improving motor performance and reliability.
Implementation Method 1
Each stator core includes... a molded soft magnetic composite material... configured to contact the heat exchanger jacket and transfer heat to the heat transfer liquid
Implementation Method 2
a heat exchanger jacket configured to circulate a heat transfer liquid
Data Source
AI summary
A stator assembly for an axial flux motor includes a heat exchanger jacket configured to circulate a heat transfer liquid. A stator also includes a plurality of stator cores each having a conductive winding, an electrically insulating material disposed over at least a portion of the conductive wire winding, and a molded soft magnetic composite (SMC) material. The heat exchanger jacket is disposed circumferentially around at least a portion of a perimeter of the stator. Each stator core defines a peripheral surface configured to contact the heat exchanger jacket and at least a portion of the peripheral surface is defined by the molded soft magnetic composite (SMC) material. Methods of making a molded soft magnetic composite (SMC) material stator core are also provided.