Moulded Stator Assembly With Bores for Shorter Heat Paths
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Solution Overview
Problem
Existing electric machine stators face challenges in effective heat dissipation due to long thermal paths, which can lead to inefficient cooling and increased manufacturing costs and time, especially in high-power applications like electric vehicles.
Innovation Solution
The introduction of bores in the dielectric material encapsulating the stator core, allowing for direct heat dissipation from the coils to the encapsulation material, combined with a heat sink featuring fins that match the bore geometry, reduces the thermal transfer path and enhances cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional dielectric encapsulation is used without bores, then the stator structure is simple and manufacturing is easy, but heat dissipation is inefficient due to long thermal paths
Solution Approach 1:
The dielectric encapsulation material is configured with a porous structure containing multiple bores extending into the axially extending slots between adjacent coils. These bores create thermal conduction pathways that significantly reduce the thermal path length from the coils to the external environment, enabling efficient heat dissipation while maintaining a relatively simple overall stator structure.
2Temperature
If bores are added to the dielectric material for improved cooling, then heat dissipation capacity increases, but manufacturing complexity and time increase
Solution Approach 1:
The bores are pre-formed within the dielectric encapsulation material during the moulding process itself, rather than being added as a separate post-processing step. This preliminary action integrates the cooling feature creation into the existing manufacturing workflow, minimizing additional manufacturing complexity and time while achieving improved cooling efficiency.
3Loss of energy
If heat is transferred through the stator core poles to the encapsulation material, then the existing thermal path is utilized, but the thermal path is particularly long and inefficient
Solution Approach 1:
Instead of relying solely on radial heat transfer through the stator core poles, the invention introduces axial heat transfer pathways through the bores that extend into the slots between adjacent coils. This dimensional change creates direct thermal conduction paths from the coil regions through the dielectric material to the external environment, significantly reducing thermal path length and energy loss.
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 improves thermal performance by increasing the heat dissipation capacity and reducing manufacturing complexity, making it suitable for high-power applications with minimal impact on production costs and time.
Implementation Method 1
the thermal conduction of the dielectric material to conduct heat away from the stator
Implementation Method 2
the provision of bores in the dielectric material increases the surface area of the external side of the material, which enhances the heat dissipating capacity of the material
Data Source
AI summary
An electric machines, a stators for an electric machines and methods of assembly associated therewith are disclosed. The stator of embodiments comprises a stator core having an annular body and a plurality of poles projecting radially from the body and a coil mounted on and surrounding each pole of the stator core. Circumferentially adjacent coils are spaced apart to define a plurality of axially extending slots between adjacent poles. A moulded dielectric material encapsulating the stator core and coils. The dielectric material defines a plurality of bores extending into the axially extending slots of the stator.