Stator Element Alternating Protrusions Heat Dissipation

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Solution Overview

Problem

Existing methods for dissipating heat from stator coils in motors are inefficient, as conductive structures can affect magnetic circuit power, resin encapsulation has limited heat conduction, and water-cooled solutions are costly and difficult to miniaturize.

Innovation Solution

A stator element with alternating protrusions on stacked housing sheets to increase air contact area for heat dissipation, combined with internal screw stud mounting grooves and resin engaging trenches for enhanced heat transfer and structural integrity, without affecting the magnetic circuit.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a conductive structure is disposed in the motor to dissipate heat, then heat dissipation capability is improved, but magnetic circuit power is affected

Engineering Contradiction:

Improveheat dissipation capabilityVSAvoidmagnetic circuit power

Core Design Contradiction:

TemperatureVSPower

Solution Approach 1:

The stator housing is segmented into multiple sheets stacked together, with heat dissipation protrusions formed on the outer peripheries of these sheets. This segmentation allows heat dissipation surfaces to be distributed across multiple stacked components, increasing total heat dissipation area without requiring a single large conductive structure that would interfere with the magnetic circuit.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heat dissipation protrusions extend radially outward from the stator housing sheets, utilizing the radial dimension to increase heat dissipation surface area. This dimensional approach allows heat dissipation to occur on the outer periphery of the stator assembly without adding axial length or interfering with the internal magnetic circuit.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Strength

If the stator coil is encapsulated in resin to dissipate heat, then structural integrity is improved, but heat dissipation effect is limited due to limited heat conduction of resin

Engineering Contradiction:

Improvestructural integrityVSAvoidheat dissipation effect

Core Design Contradiction:

StrengthVSTemperature

Solution Approach 1:

The heat dissipation protrusions act as intermediary structures between the resin-encapsulated stator coil and the external environment. These protrusions extend through the resin encapsulation material, providing thermal pathways that conduct heat from the coil, through the resin, and out to the surrounding air on the outer periphery of the stator assembly.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Temperature

If a water-cooled passage is disposed in the housing to dissipate heat, then heat dissipation capability is improved, but costs increase and miniaturization becomes difficult

Engineering Contradiction:

Improveheat dissipation capabilityVSAvoidcosts and miniaturization difficulty

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The complex water-cooled passage system is extracted and replaced with a simpler air-cooling approach using heat dissipation protrusions. Instead of incorporating internal fluid channels and pumps, the design extracts heat dissipation to the outer periphery of the stator assembly through protruding structures, eliminating the need for water cooling infrastructure while maintaining effective heat dissipation.

Inventive Principle:

Principle #2Taking out (Extraction)

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 provides a strong heat dissipation capability at lower costs, enhancing motor efficiency and reliability while maintaining compact design.

Implementation Method 1

protrusions of the adjacent stator housing sheets are alternately arranged in a direction in which the at least two stator housing sheets are stacked, to increase a contact area between the projections and air outside the stator element, thereby dissipating heat of the stator disposed inside the stator element

Methodology Applied

Scientific EffectHeat dissipation: Convection

Data Source

PatentUS11296562B2Stator element, stator assembly, motor, and electromechanical device

Publication Date: 2022.04.05 NIDEC CORP(JP)

AI summary

Embodiments of this application provide a stator element, a stator assembly, a motor, and an electromechanical device, the stator element including at least two stacked stator housing sheets, each of the stator housing sheets being a frame enclosed by a sheet periphery, at least two protrusions being disposed around the periphery of each of the stator housing sheets, the protrusion being directed from an inside of the stator housing sheet to an outside of the stator housing sheet, a groove being formed between adjacent protrusions, and protrusions of the adjacent stator housing sheets being alternately arranged in a direction in which the at least two stator housing sheets are stacked. Therefore, heat of a stator disposed inside the stator element can be dissipated with a strong heat dissipation capability at relatively low costs.