Stator Cooling Channel Embedded in Thermally Treated Material
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Solution Overview
Problem
Existing electrical machines and stators face inefficiencies in cooling due to suboptimal heat transfer and complex manufacturing processes, particularly with traditional methods that do not effectively integrate cooling channels and magnetic field guidance within a single thermally conductive material.
Innovation Solution
A stator design incorporating a meandering cooling channel embedded within a thermally influenced material, such as plastics or aluminum, which also includes an iron-containing body for magnetic field guidance, utilizing methods like injection molding, casting, or 3-D printing to enhance heat conduction and simplify manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling channels are merely set into bores of a stator lamination stack, then the manufacturing process is simple, but the heat-conducting contact between the cooling channel and the stator is insufficient
Solution Approach 1:
The patent merges the cooling channel and the stator into a single integrated component by embedding the cooling channel directly within the stator body during manufacturing. This eliminates the need for separate assembly steps and ensures optimal thermal contact between the cooling channel and the magnetic field guidance structure, resolving the contradiction between cooling efficiency and manufacturing complexity.
2Temperature
If a meandering cooling channel is embedded in a thermally treated material with an iron-containing body, then heat conduction is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies preliminary action by pre-forming the meandering cooling channel within the stator body during the manufacturing process itself, rather than attempting to install it afterward. The thermally treated material and iron-containing body are prepared in advance with the cooling channel already embedded, ensuring optimal heat transfer paths are established before the stator is put into service.
3Strength
If the element for embedding is made of sintered material, then structural strength and heat resistance are improved, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes parameter changes by employing sintered material with specific thermal and mechanical properties. The sintering process transforms powdered material into a dense, strength-optimized structure that can withstand high temperatures while maintaining structural integrity. This parameter optimization allows the embedding element to achieve both high strength and heat resistance through controlled material density and composition.
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 design improves heat transfer and cooling efficiency by creating a snug, thermally conductive interface between the cooling channel and the stator's magnetic field guidance, while simplifying the manufacturing process and allowing for a more compact and efficient electrical machine structure.
Implementation Method 1
The embedding provides a good heat-conducting contact between the embedding material and the cooling channel
Implementation Method 2
Using a meandering cooling channel, a fluid can be deflected in the flow direction thereof for cooling the electrical machine or the stator
Data Source
AI summary
The invention relates to a stator (1) of an electrical machine (10), the electrical machine (10) itself, and a manufacturing method. The stator (1) has a meandering cooling channel (18), wherein the meandering cooling channel (18) is embedded in an element (22), wherein the element (22) comprises a material which is influenced thermally so as to form a shape of the element (22), wherein an iron-containing body (3), for guiding a magnetic field of the stator, is embedded in the element (22).