Stator Terminal Connector Baffle for End-Winding Cooling
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Solution Overview
Problem
Existing electric motors in electrified vehicle powertrains face challenges in efficiently distributing coolant around the end windings, leading to potential overheating and reduced performance.
Innovation Solution
A terminal connector with a cylindrical baffle and a non-conductive frame is used to distribute coolant around the end windings of the electric motor, enhancing cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional terminal connectors without baffles are used, then the structure is simple, but coolant distribution around end windings is poor leading to overheating
Solution Approach 1:
The terminal connector is segmented into functional zones using a baffle that divides the coolant flow path. The baffle creates separate regions for coolant inlet and outlet, ensuring directed flow around the end windings. This segmentation improves coolant distribution effectiveness without requiring complete redesign of the terminal connector.
Solution Approach 2:
The terminal connector is designed to perform multiple functions: electrical connection, mechanical support, and coolant flow management. By integrating the baffle and coolant channels into the terminal connector housing, the component serves both electrical and thermal management purposes, improving coolant distribution without adding separate dedicated cooling components.
2Temperature
If coolant channels are added to improve cooling, then cooling efficiency increases, but manufacturing complexity increases
Solution Approach 1:
The coolant channels and baffle structures are merged into the terminal connector housing as an integrated component. This combining approach allows the coolant flow paths to be formed during the same manufacturing process as the terminal connector body, reducing the number of separate parts and assembly steps while maintaining effective cooling functionality.
Solution Approach 2:
The terminal connector housing is designed with integrated thin-walled coolant channels that are formed as part of the housing structure. These thin-film channels provide effective coolant flow paths while minimizing material usage and manufacturing complexity, allowing efficient cooling without requiring thick or complex channel structures.
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 proposed solution effectively distributes coolant around the end windings, improving the cooling efficiency of the electric motor and enhancing its performance and reliability.
Implementation Method 1
A terminal connector with a cylindrical baffle and a non-conductive frame is used to distribute coolant around the end windings of the electric motor, enhancing cooling efficiency
Implementation Method 2
Some of the electrical power is converted to heat due to electrical resistance in the windings
Data Source
AI summary
A stator for an electric motor of a vehicle utilizes a molded terminal connector. The molded terminal connector also serves as a baffle to distribute cooling fluid around end windings of the stator. The molded terminal connector includes a non-conductive cylindrical portion and frame into which the electrically conductive terminals are molded. The terminals include a winding link that is electrically connected to the end windings and a power link that is electrically connected to the inverter.