Stator Laminated Core Interlock Structure for Liquid-Cooling Pressure

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Laminated cores with stacked sheet metal parts face challenges in maintaining gap-free structures under high hydraulic pressures, especially when subjected to liquid cooling, which is necessary for high-performance applications.

Innovation Solution

The laminated core design incorporates protrusions that completely surround the longitudinal axis, ensuring a barrier against liquid penetration, and can be produced using known methods like clinching, with optional sealing compounds to enhance durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If hot-melt adhesive varnish is used to bond stacked sheet metal parts, then the layers are bonded together, but gaps may still form under high hydraulic pressure

Engineering Contradiction:

Improvebond strengthVSAvoidgap-free structure

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The sheet metal parts are segmented with protrusions that extend through the adhesive layer, creating discrete mechanical interlocking points that prevent gap formation under pressure, supplementing the adhesive bonding

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bonding system combines hot-melt adhesive varnish with mechanical protrusion-interlock features, creating a composite bonding mechanism that leverages both chemical adhesion and mechanical interlocking to ensure gap-free structure under high pressure

Inventive Principle:

Principle #40Composite materials

2Reliability

If protrusions are added to sheet metal parts to prevent gaps, then pressure resistance improves, but manufacturing complexity increases

Engineering Contradiction:

Improvepressure resistanceVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The protrusions are designed with specific dimensional parameters (height, diameter, spacing) that optimize pressure resistance while maintaining manufacturability through standard forming processes

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The protrusions are formed as integral features of the thin sheet metal parts using forming processes, adding structural functionality without requiring separate components or complex assembly steps

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If protrusions completely surround the longitudinal axis, then liquid penetration is prevented, but manufacturing precision requirements increase

Engineering Contradiction:

Improvesealing performanceVSAvoidprotrusion alignment

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The protrusions extend slightly beyond what is minimally required to touch adjacent layers, providing excessive mechanical interlocking that compensates for manufacturing tolerances and ensures complete circumferential coverage

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The protrusion design inherently cushions against misalignment by providing mechanical interlocking that accommodates manufacturing variations, preventing gap formation even when perfect alignment is not achieved

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS20260005554A1Laminated core, more particularly for a stator of an electric machine, and method for producing said laminated core

Publication Date: 2026.01.01 VOESTALPINE STAHL GMBH

AI summary

A laminated core, more particularly for a stator of an electric machine, and method for producing said laminated core. The laminated core has several layers stacked one atop another, wherein the layers are each made up of either an individual sheet metal part or several sheet metal parts positioned next to one another and each sheet metal part has a protrusion and with the aid of these protrusions, the layers engage with one another. It is proposed, in the case of a single sheet metal part making up a layer, for the protrusion to be embodied as completely surrounding the longitudinal axis of the laminated core or, in the case of several sheet metal parts positioned next to one another making up a layer, for the protrusions of these sheet metal parts to be embodied as combining to completely surround the longitudinal axis of the laminated core.