Stator Coating Directing Coolant Flow
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Solution Overview
Problem
Current thermal management systems for electric machines and power inverters face inefficiencies due to non-uniform coolant flow distribution, which limits performance and increases temperature constraints, particularly in harsh environments.
Innovation Solution
The application of oleophobic or hydrophobic patterned coatings on the stator core of electric machines to direct coolant flow, combined with oleophilic or hydrophilic coatings, creates controlled flow paths that enhance coolant distribution and reduce friction, allowing for more efficient heat removal without the need for physical channels or fixtures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If physical channels or fixtures are used to direct coolant flow, then coolant distribution can be controlled, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent replaces mechanical coolant distribution systems (physical channels and fixtures) with a chemical/coating-based system. Oleophobic or hydrophobic coatings are applied to the stator core surface to create regions that repel coolant, while oleophilic or hydrophilic coatings create regions that attract coolant. This substitution eliminates the need for complex physical channel structures while achieving controlled coolant flow distribution to critical areas.
Solution Approach 2:
The patent changes the surface energy parameters of the stator core by applying different coating materials. By modifying the chemical composition and surface properties of the stator core through coating application, the coolant flow behavior is controlled without mechanical structures. The coating materials create regions with different wettability characteristics, directing coolant flow based on surface energy differences rather than physical channel geometry.
2Temperature
If coolant flow is increased to remove heat, then thermal management improves, but friction losses and power consumption increase
Solution Approach 1:
The patent applies local quality by creating spatially varying coating properties on the stator core surface. Oleophobic or hydrophobic coatings are applied in regions where coolant flow should be minimized, while oleophilic or hydrophilic coatings are applied in regions where coolant flow should be enhanced. This localized differentiation allows efficient heat removal from critical areas without increasing overall coolant flow and associated friction losses throughout the entire system.
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 management by ensuring uniform coolant flow, reducing friction and heat generation, and enhancing the reliability and efficiency of electric machines by directing coolant to critical areas, thus reducing power losses and eliminating localized hot spots.
Implementation Method 1
one or more layers of an oleophobic or hydrophobic patterned coating defining boundaries wrapping around a perimeter of the stator core
Implementation Method 2
one or more layers of an oleophilic or hydrophilic coating on the portion within the boundaries configured to direct coolant flow over the oleophilic or hydrophilic coating within the boundaries
Data Source
AI summary
An electric machine is disclosed. The electric machine includes a stator core within a transaxle housing and having a channel-less outer surface portion. The electric machine also includes one or more layers of an oleophobic or hydrophobic patterned coating defining boundaries wrapping around a perimeter of the stator core, and one or more layers of an oleophilic or hydrophilic coating on the portion within the boundaries configured to direct coolant flow over the oleophilic or hydrophilic coating within the boundaries.