Stator Core Cooling Structure With Network Flow Channels

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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 power performance and size of electric vehicle motors.

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 increasing power requirements of electric vehicles

Engineering Contradiction:

Improveheat dissipation capacityVSAvoidpower density

Core Design Contradiction:

TemperatureVSPower

Solution Approach 1:

The stator core is divided into multiple core punching sheets (at least two) with different outer peripheral surface structures. Each sheet has convex parts and concave parts that are staggeredly arranged, creating segmented flow channels that force the cooling liquid to flow in series through multiple paths, increasing overall heat dissipation capacity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention transitions from traditional single-dimension cooling channels to a multi-dimensional network-shaped cooling system. The flow channels extend in radial, axial, and circumferential directions, creating a three-dimensional cooling network that significantly increases the heat dissipation surface area and improves cooling efficiency

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Power

If high-performance ferromagnetic materials are chosen to improve torque density, then power performance increases, but heat dissipation becomes more challenging and requires better cooling systems

Engineering Contradiction:

Improvetorque densityVSAvoidheat dissipation efficiency

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

The stator core is segmented into multiple core punching sheets with staggered convex and concave parts, creating multiple series flow channels that increase the total heat dissipation surface area, enabling better heat dissipation for high-performance materials

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The network-shaped cooling flow channels are nested within the stator core structure itself, with the flow channels formed by the convex and concave parts of the core punching sheets. The cooling system is integrated into the core rather than being an external addition, improving heat dissipation efficiency

Inventive Principle:

Principle #7Nested doll (Nesting)

3Volume of moving object

If the motor size is reduced for lightweight and miniaturization, then vehicle integration improves, but heat dissipation capacity decreases

Engineering Contradiction:

Improvemotor sizeVSAvoidheat dissipation capacity

Core Design Contradiction:

Volume of moving objectVSTemperature

Solution Approach 1:

The cooling system utilizes three-dimensional flow channels that extend in multiple directions (radial, axial, circumferential) within the compact stator core, maximizing heat dissipation surface area within a limited volume and enabling effective cooling in miniaturized motors

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The convex and concave parts are strategically distributed on the outer peripheral surfaces of the core punching sheets, creating localized heat dissipation zones that are optimized for the specific thermal load distribution in different regions of the stator core

Inventive Principle:

Principle #3Local quality

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 cost.

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

an outer side wall of the stator core is provided with multiple heat dissipation protrusions, and the multiple heat dissipation protrusions are staggeredly arranged in a network-shaped form

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS20250373094A1Stator Core, Motor, Power Assembly, Automobile and Vehicle

Publication Date: 2025.12.04 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.