Stator Cooling Channel Layout With Thermally Conductive Plastic
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Solution Overview
Problem
Conventional electrical machines require significant structural expenditure for efficient heat transfer from the stator to the coolant, leading to increased manufacturing costs.
Innovation Solution
Embedding stator windings and cooling channels within a thermally conductive and electrically insulating plastic, which acts as a heat transfer medium and prevents electrical short-circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling devices with separate cooling channels are used, then heat transfer from stator to coolant is achieved, but structural expenditure and manufacturing costs increase significantly
Solution Approach 1:
The patent merges the cooling channel structure with the stator winding support structure by embedding both elements directly into the plastic stator. This integration eliminates the need for separate cooling devices and complex mounting arrangements, thereby reducing structural expenditure while maintaining effective heat transfer from stator to coolant.
Solution Approach 2:
The patent utilizes plastic as a composite material that combines electrical insulation properties with thermal conduction capabilities. This allows the stator to simultaneously serve as an electrical insulator and a heat transfer medium, eliminating the need for additional structural components and reducing overall device complexity.
2Ease of manufacture
If plastic is used as heat transfer medium, then structural design is simplified and manufacturing costs are reduced, but electrical insulation between stator windings and coolant must be ensured
Solution Approach 1:
The patent employs plastic as a composite material that inherently possesses both electrical insulation properties and sufficient thermal conduction capabilities. This dual-function material eliminates the need for separate insulation components between stator windings and coolant, simplifying the structural design and reducing manufacturing costs while maintaining reliable electrical insulation.
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 approach enables effective cooling of stator windings, preventing overheating and damage to the electrical machine, while reducing manufacturing costs through simplified structural design.
Implementation Method 1
a plastic for transferring heat from the stator winding to the cooling channel is arranged in the intermediate space
Implementation Method 2
a plastic which typically intrinsically combines electrically insulating and thermally conductive properties
Data Source
AI summary
An electrical machine may include a rotor rotatable about an axis of rotation, by way of which an axial direction of the electrical machine may be defined, a stator having electrically conductive stator windings, and at least one cooling channel through which a coolant may be flowable for cooling the stator windings. The stator may have stator teeth extending along the axial direction, arranged spaced apart from another along a circumferential direction of the rotor, and bearing the stator windings. The at least one cooling channel and at least one stator winding may be arranged in at least one intermediate space formed between two stator teeth adjacent in the circumferential direction. A plastic for transferring heat from the at least one stator winding to the at least one cooling channel may be arranged in the at least one intermediate space.