Stator Core Cooling Channel Layout for High Power Density Motors

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Solution Overview

Problem

Existing automobile motor cooling technologies, particularly oil cooling, have limited heat dissipation capacity and efficiency, which affects the motor's performance and size, especially in electric vehicles where compactness and power density are critical.

Innovation Solution

A motor design featuring a network-shaped cooling flow channel between the stator core and casing, with heat dissipation protrusions on the stator core and casing, and a waterfall-spray mechanism for end windings, enhancing heat dissipation through turbulent fluid flow and increased surface area.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If traditional cooling methods (natural cooling, air cooling, water cooling, oil cooling) are used, then the motor can operate, but the heat dissipation capacity is limited and cannot meet the requirements for high torque density and power density

Engineering Contradiction:

Improveheat dissipation capacityVSAvoidtorque density and power density

Core Design Contradiction:

TemperatureVSProductivity

Solution Approach 1:

The cooling flow channel is segmented into multiple independent channels arranged in parallel, allowing cooling fluid to flow through multiple paths simultaneously. This segmentation increases the total heat dissipation surface area and improves heat dissipation capacity without increasing motor size, thereby enabling higher torque density and power density

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cooling flow channels are arranged in a multi-dimensional network structure within the stator core, utilizing radial, axial, and circumferential directions. This spatial arrangement maximizes heat dissipation surface area within the limited motor volume, improving heat dissipation capacity while maintaining compact dimensions for high power density

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Productivity

If high-performance ferromagnetic materials are used to improve torque density, then the motor performance improves, but heat dissipation capacity needs to be enhanced to protect electronic components and insulating materials

Engineering Contradiction:

Improvetorque densityVSAvoidprotection of electronic components and insulating materials

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Cooling fluid is introduced into the cooling flow channels before the motor reaches critical temperature levels, proactively preventing overheating of electronic components and insulating materials. This preliminary cooling action ensures reliable operation when high-performance ferromagnetic materials are used to achieve high torque density

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The cooling fluid acts as an intermediary medium that transfers heat away from the stator core and electronic components. This intermediary cooling system protects sensitive components while allowing the motor to operate at high torque density using high-performance ferromagnetic materials

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Improves heat dissipation capacity and efficiency, reducing motor temperatures and maintaining performance while minimizing size and weight, thus optimizing power density and torque density.

Implementation Method 1

a slit flow channel is formed between an outer side wall of the stator core and an inner side wall of the casing, and the slit flow channel is provided as a network-shaped cooling flow channel for a cooling fluid to flow

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

the multiple heat dissipation protrusions are staggeredly arranged in a network-shaped form

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

enhancing heat dissipation through turbulent fluid flow and increased surface area

Methodology Applied

Scientific EffectTurbulence: Turbulence

Implementation Method 4

a waterfall-spray mechanism for end windings, enhancing heat dissipation through turbulent fluid flow and increased surface area

Methodology Applied

Scientific EffectFluid spray: Fluid Spray

Data Source

PatentUS12418206B2Stator core, motor, power assembly, automobile and vehicle

Publication Date: 2025.09.16 WUXI INFIMOTION TECH CO LTD

AI summary

A stator core, a motor, a power assembly, an automobile and a vehicle are provided. The motor includes: a casing; a stator core fixed in the casing, and a slit flow channel is formed between an outer side wall of the stator core and an inner side wall of the casing, and the slit flow channel is provided as a network-shaped cooling flow channel for cooling fluid to flow; a stator winding mounted on the stator core; and a rotor rotatably sleeved on an inner side of the stator core. A flow path of the cooling fluid in the network-shaped cooling channel is also network-shaped, and a flow form of the cooling fluid in the network-shaped path is turbulent.