Heat Dissipation Cap for Stator Coil Thermal Management
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Solution Overview
Problem
The existing heat dissipation systems for motors face inefficiencies in transferring heat from the stator coil to the cooling units due to exposed ends of the wound coil, leading to reduced electromagnetic force and driving efficiency, and require additional insulation and manufacturing steps that increase costs and complexity.
Innovation Solution
A heat dissipation cap with a heat radiation exterior member and a heat transfer filling material is coupled to the stator core to accommodate protruding ends of the wound coil, enhancing heat transfer paths and mechanical strength, while providing insulation and thermal conductivity, thus improving heat dissipation efficiency and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If cooling units are provided in housing or between housing and stator outer surface, then heat dissipation is performed, but heat transfer from wound coil to cooling units is inefficient due to exposed coil ends, resulting in reduced electromagnetic force and driving efficiency
Solution Approach 1:
The invention extracts the heat dissipation function from the housing-based cooling units and creates a dedicated heat dissipation cap that directly contacts the wound coil. This separate heat dissipation component is coupled to the stator core, allowing efficient heat transfer from the coil ends to the cap, which then conducts heat to the housing. This resolves the contradiction by providing a specialized heat transfer path that maintains electromagnetic force while improving heat dissipation efficiency.
Solution Approach 2:
The heat dissipation cap acts as an intermediary component between the wound coil and the housing cooling units. It includes a heat transfer filling material that fills the space between the coil and cap, and a heat radiation exterior member that contacts the housing. This intermediary structure enables efficient heat transfer from the exposed coil ends through the cap to the housing, resolving the heat transfer inefficiency while maintaining system reliability.
2Loss of energy
If heat dissipation cap is coupled to stator core to improve heat transfer, then heat dissipation efficiency increases, but manufacturing time and cost increase due to additional steps
Solution Approach 1:
The invention merges multiple functions into the heat dissipation cap: it provides heat transfer, structural support for the coil ends, and insulation. The cap is designed as an integrated component that couples to the stator core and accommodates the wound coil ends in a single assembly, reducing the need for separate manufacturing steps and components while improving heat dissipation efficiency.
Solution Approach 2:
The heat dissipation cap serves multiple functions simultaneously: it acts as a heat transfer medium, provides mechanical support for the coil ends, offers insulation, and facilitates cooling. This multi-functionality reduces the overall component count and manufacturing complexity, allowing improved heat dissipation without proportionally increasing manufacturing time and cost.
3Reliability
If additional insulation coating is performed on wound coil end, then insulation is provided, but manufacturing complexity and cost increase
Solution Approach 1:
The invention combines the insulation function with the heat dissipation cap structure. The cap itself, made of insulating material, provides the necessary insulation for the wound coil ends without requiring an additional separate insulation coating step. This integration maintains reliable insulation properties while simplifying the manufacturing process and reducing 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 heat dissipation cap effectively extends heat transfer paths, reduces manufacturing time and costs, and enhances durability against vibrations and high temperatures, while offering superior insulation properties, even without additional insulation coatings, thereby improving motor efficiency and longevity.
Implementation Method 1
a heat transfer filling material which fills a space between the heat radiation exterior member and the accommodated wound coil
Implementation Method 2
a heat radiation exterior member molded to have an accommodation portion which accommodates one protruding end portion of the wound coil
Data Source
AI summary
Provided is a stator assembly comprising a stator including a stator core having a cylindrical shape and a through hole through which two ends communicate with an outside and a wound coil having parts protruding to the outside further than the two ends of the stator core in an axial direction of the stator core and the remaining part positioned in the stator core and heat dissipation caps which are provided on two end portions of the stator core such that the protruding parts of the wound coil are accommodated in contact with an outer surface of the stator core. Therefore, a heat radiation path capable of transferring heat generated by or transferred to a stator coil to the outside increases, heat dissipation efficiency is improved, heat dissipation properties are superior, and thus a decrease in operational efficiency of a motor due to heat generation may be minimized or prevented.