Stator Cooling Channels for Low-Leakage Coil Heat Dissipation

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Solution Overview

Problem

Conventional motor cooling systems face high leakage risks and inefficiencies due to complex fittings and manufacturing tolerances, leading to inadequate heat dissipation and potential motor damage.

Innovation Solution

A stator design with reduced fittings, featuring a stator core with axial gaps forming coolant flow channels and end plates with nozzles for efficient coolant distribution, which reduces leakage risk and enhances heat dissipation by allowing coolant to flow directly to the coil winding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a spray ring is used to spray coolant to the coil winding, then heat dissipation capability is improved, but the quantity of fittings increases and leakage risk increases

Engineering Contradiction:

Improveheat dissipation capabilityVSAvoidquantity of fittings

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent integrates the spray ring function directly into the stator core by forming coolant flow channels within the stator core structure itself. The gaps between adjacent stator core teeth serve as the coolant flow channels, eliminating the need for separate spray rings and reducing the quantity of fittings while maintaining heat dissipation capability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The stator core structure serves dual purposes: it provides magnetic flux paths through the teeth and simultaneously acts as the coolant distribution system through its inherent gaps. The stator core structure itself creates and directs the coolant flow, making the system self-sufficient and reducing external fittings

Inventive Principle:

Principle #25Self-service

2Temperature

If a spray ring is used to spray coolant, then heat dissipation is improved, but leakage risk increases due to sealing requirements

Engineering Contradiction:

Improveheat dissipation capabilityVSAvoidleakage risk

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

By merging the coolant flow channel function into the stator core structure itself, the patent eliminates multiple sealing interfaces between separate components (spray ring, stator core, housing). The integrated structure has fewer joints and sealing surfaces, thereby reducing leakage risk while maintaining effective coolant delivery to the coil winding

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts the coolant flow channel function from separate fittings and embeds it directly into the stator core structure. This removes the need for external spray rings and associated sealing components, reducing leakage risk by eliminating potential failure points

Inventive Principle:

Principle #2Taking out (Extraction)

3Temperature

If a spray ring is used for cooling, then heat dissipation is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improveheat dissipation capabilityVSAvoiddimension precision

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The coolant flow channels are formed as integral parts of the stator core structure, utilizing the natural gaps between stator core teeth. This integration eliminates the need for separate precision-machined spray rings and their associated sealing surfaces, reducing manufacturing precision requirements while maintaining effective coolant flow and heat dissipation

Inventive Principle:

Principle #5Merging (Combining)

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 solution improves heat dissipation efficiency, reduces the risk of coolant leakage, and extends motor service life while simplifying the structure and assembly process, making it cost-effective.

Implementation Method 1

the coolant is configured to cool the stator core, and then is sprayed to the coil winding to cool the coil winding

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

the plurality of gaps are arranged in a circumferential direction of the stator core, and each gap penetrates the stator core along the axial direction

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20250007339A1Stator, motor, powertrain, and mechanical device

Publication Date: 2025.01.02 HUAWEI DIGITAL POWER TECH CO LTD

AI summary

A stator, a motor, a powertrain, and a mechanical device. The stator includes a stator core, a coil winding, a first end plate, and a second end plate. The stator core includes a plurality of gaps extending along an axial direction, to form first coolant flow channels. The first coolant flow channel communicates with a liquid inlet region of the stator core. End faces of two ends of the stator core along the axial direction are respectively a first end face and a second end face. The first end plate is mounted on the first end face, and the second end plate is mounted on the second end face. A second coolant flow channel is formed between the first end plate and the first end face. A quantity of fittings of the motor is small, a leakage risk is low, and heat dissipation effect is good.